AGE-HARDENABLE AND HIGHLY FORMABLE ALUMINUM ALLOYS, MONOLITHIC SHEET MADE THEROF AND CLAD ALUMINUM ALLOY PRODUCT COMPRISING IT

ALLIAGES D'ALUMINIUM DURCISSABLES PAR VIEILLISSEMENT ET A FORMABILITE ELEVEE, FEUILLE MONOLITHIQUE FABRIQUEE A PARTIR DE CES DERNIERS ET PRODUIT EN ALLIAGE D'ALUMINIUM PLAQUE LA COMPRENANT

English Abstract

Provided herein are new aluminum alloy products and methods of making these alloys. The aluminum alloy products are age-hardenable, display high strength and formability, and allow for the use of recycled scrap. The aluminum alloys can serve as the core in a clad aluminum alloy product. The alloy products can be used in a variety of applications, including automotive, transportation, and electronics applications.

French Abstract

L'invention concerne de nouveaux produits en alliage d'aluminium plaqué et des procédés de production de ces alliages. Les produits en alliage d'aluminium sont durcissables par vieillissement, présentent une résistance et une formabilité élevées et permettent l'utilisation de déchets métalliques recyclés. Les alliages d'aluminium peuvent servir de noyau dans un produit en alliage d'aluminium plaqué. Les produits en alliage peuvent être utilisés dans diverses applications, notamment dans l'automobile, les transports et les applications électroniques.

Claims

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
WHAT IS CLAIMED IS:
1. An aluminum alloy, comprising:
from 0.5 wt. % to 1.6 wt. % Mg;
from 0.2 wt. % to 0.5 wt. % Si;
up to 1.0 wt. % Fe;
up to 0.5 wt. % Cu;
up to 0.5 wt. % Mn;
up to 0.3 wt. % Cr;
up to 0.3 wt. % Ti;
up to 0.5 wt. % Zn;
up to 0.25 wt. % impurities; and
Al.
2. The aluminum alloy of claim 1, wherein:
the amount of Mg is from 0.6 wt. % to 1.5 wt. %;
the amount of Si is from 0.3 wt. % to 0.45 wt. %;
the amount of Fe is up to 0.5 wt. %;
the amount of Cu is up to 0.4 wt. %;
the amount of Mn is up to 0.4 wt. %;
the amount of Cr is up to 0.25 wt. %;
the amount of Ti is up to 0.15 wt. %;
the amount of Zn is up to 0.4 wt. %; and
the amount of impurities is up to 0.20 wt. %.
3. The aluminum alloy of claim 1 or 2, wherein the Mg and Si are present in
a ratio of
from 5:1 to 2:1 of Mg to Si by weight, preferably from 4:1 to 2:1.
-35-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
4. The aluminum alloy of any of the preceding claims, wherein:
the amount of Mg is from 0.7 wt. % to 1.5 wt. %;
the amount of Si is from 0.25 wt. % to 0.45 wt. %;
the amount of Fe is from 0.01 wt. % to 1.0 wt. %;
the amount of Cu is from 0.01 wt. % to 0.5 wt. %;
the amount of Mn is from 0.01 wt. % to 0.5 wt. %;
the amount of Cr is from 0.005 wt. % to 0.3 wt. %;
the amount of Ti is from 0.01 wt. % to 0.25 wt. %;
the amount of Zn is up to 0.4 wt. %; and
the amount of impurities is up to 0.20 wt. %.
5. The aluminum alloy of any of the preceding claims, wherein the aluminum
alloy, when
in a T8x temper, has a yield strength (Rp0.2) of from 160 MPa to 230 MPa when
tested
according to ISO 6892-1 (2016).
6. The aluminum alloy of any of the preceding claims, wherein the aluminum
alloy has a
bake hardening value from 70 MPa to 140 MN.
7. The aluminum alloy of any of the preceding claims, comprising at least
40 wt. %
recycled content.
8. The aluminum alloy of any of the preceding claims, comprising at least
40 wt. % UBC.
9. The aluminum alloy of any of the preceding claims, wherein the combined
concentration of Fe, Mn and Cu in the aluminum alloy is at least 0.7 wt. %,
preferably from
0.7 wt.% and 3.0 wt.%.
-36-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
10. The aluminum alloy of any of the preceding claims, wherein the aluminum
alloy is a
core layer in a clad product.
11. A monolithic sheet, comprising the aluminum alloy of any of the
preceding claims.
12. A clad aluminum alloy product, comprising:
a core layer having a first side and a second side; and
a first clad layer in contact with the first side of the core layer;
wherein the core layer comprises from 0.5 wt. % to 1.6 wt. % Mg and from 0.2
wt. %
to 0.5 wt. % Si.
13. The clad aluminum alloy product of claim 12, wherein the first clad
layer has a
thickness of from 0.05 mm to 0.80 mm.
14. The clad aluminum alloy product of any of claims 12-13, wherein the
core layer has a
thickness of from 0.7 to 2.3 mm.
15. The clad aluminum alloy product of any of claims 12-14, wherein the
clad aluminum
alloy product is a sheet, a plate, an electronic device housing, an automotive
structural part, an
aerospace structural part, an aerospace non-structural part, a marine
structural part, or a marine
non-structural part.
-37-

Description

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
AGE-HARDENABLE AND HIGHLY FORMABLE ALUMINUM ALLOYS, MONOLITHIC SHEET MADE
THEROF AND CLAD
ALUMINUM ALLOY PRODUCT COMPRISING IT
PRIORITY CLAIM
[0001] This application claims priority to U.S. Provisional Application No.
62/817,713,
filed on March 13, 2019, the entire contents and disclosure of which are
incorporated herein.
FIELD
[0002] Provided herein are novel aluminum alloys, products made from these
novel
alloys, and methods of making these alloys and products. The new aluminum
alloys and
products are suitable for a variety of applications, including automotive and
electronic
applications. The aluminum alloys can serve as a monolithic product, as a core
layer in a clad
aluminum alloy product or as a clad layer in a clad aluminum alloy product,
for example. The
aluminum alloy products are age-hardenable, display high strength and
formability, and allow
for the use of recycled scrap.
BACKGROUND
[0003] Current highly formable alloys are, for example, 6xxx series
aluminum alloys
with high silicon levels, or 5xxx series aluminum alloys that have no age
hardening potential.
Adding silicon to 5xxx series aluminum alloys in an attempt to make them age-
hardenable
fails because 5xxx series aluminum alloys have very limited solubility for
silicon, even at
high temperature. Thus, a solutionizing treatment is not feasible and age
hardening does not
work. Accordingly, highly formable alloys with high strength and the ability
to be age
hardened are desirable.
[0004] Further, it is advantageous if aluminum alloys can incorporate
recycled scrap.
Incorporating recycled scrap leads to decreased cost and time associated with
producing
primary aluminum, as well as the desirability of recycling. Recycled scrap,
however, may be
unsuitable for use in preparing high performance aluminum alloys as the
recycled scrap may
contain high levels of certain undesirable elements. For example, the recycled
scrap may
include certain elements in amounts that affect the mechanical properties of
the aluminum
alloys, such as formability and strength.
-1-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
SUMMARY
[0005] Covered embodiments of the invention are defined by the claims, not
this
summary. This summary is a high-level overview of various aspects of the
invention and
introduces some of the concepts that are further described in the Detailed
Description section
below. This summary is not intended to identify key or essential features of
the claimed
subject matter, nor is it intended to be used in isolation to determine the
scope of the claimed
subject matter. The subject matter should be understood by reference to
appropriate portions
of the entire specification, any or all drawings, and each claim.
[0006] Provided herein are new aluminum alloys and aluminum alloy products
and
methods of making these aluminum alloys and products. The aluminum alloys and
products
possess a combination of high formability, high strength, age-hardenability,
and allow for the
use of recycled materials in their formation. The aluminum alloys as described
herein
comprise magnesium (Mg) and silicon (Si), among other optional elements. Thus,
in some
aspects, the aluminum alloys as described herein can comprising from about 0.5
wt. % to
about 1.6 wt. % Mg; from about 0.2 wt. % to about 0.5 wt. % Si; up to about
1.0 wt. % Fe; up
to about 0.5 wt. % Cu; up to about 0.5 wt. % Mn; up to about 0.3 wt. % Cr; up
to about 0.3
wt. % Ti; up to about 0.5 wt. % Zn; up to about 0.25 wt. % impurities; and Al.
In some
aspects, the weight ratio of Mg to Si in the aluminum alloy can be from about
8:1 to about
1.5:1.
[0007] The aluminum alloys as described herein can serve as a monolithic
product, such
as a sheet, a shate, or a plate, comprising the aluminum alloys described
herein. The
aluminum alloys as described herein can also serve as the core layer in a clad
metal product,
for example. Such core layers (comprising the aluminum alloys described
herein) can be
combined with at least one clad layer to form the clad metal product. The
aluminum alloys as
described herein can also serve as the clad layer in a clad metal product, for
example. The
clad aluminum alloy products can include automotive products (e.g., automotive
structural
parts), aerospace products (e.g., an aerospace structural part or an aerospace
non-structural
part), marine products (e.g., a marine structural part or a marine non-
structural part), or
electronic products (e.g., electronic device housings), as examples. Further
provided are
aluminum alloy sheets, plates, and shates comprising a clad aluminum alloy
product as
described herein.
[0008] Other objects and advantages will be apparent from the following
detailed
description of non-limiting examples.
-2-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
BRIEF DESCRIPTION OF THE FIGURES
[0009] FIG. 1 is a graph of total elongation (A80) in longitudinal (L),
diagonal (D), and
transverse (T) directions for aluminum alloy samples.
[0010] FIG. 2 is a graph of uniform elongation (Ag) in longitudinal (L),
diagonal (D), and
transverse (T) directions for aluminum alloy samples.
[0011] FIG. 3 is a graph of total elongation (A80) in longitudinal (L),
diagonal (D), and
transverse (T) directions for aluminum alloy samples.
[0012] FIG. 4 is a graph of uniform elongation (Ag) in longitudinal (L),
diagonal (D), and
transverse (T) directions for aluminum alloy samples.
[0013] FIG. 5 is a graph showing r (10-15) values in longitudinal (L),
diagonal (D), and
transverse (T) directions for aluminum alloy samples.
[0014] FIG. 6 is a graph showing r (10-15) values in longitudinal (L),
diagonal (D), and
transverse (T) directions for aluminum alloy samples.
[0015] FIG. 7 is a graph showing bending behavior as measured by f-factor
at 10% and
15% for aluminum alloy samples.
DETAILED DESCRIPTION
[0016] Described herein are new aluminum alloys and aluminum alloy products
that
comprise amounts of aluminum (Al), magnesium (Mg), and Silicon (Si), along
with other
elements. In some aspects, the new aluminum alloys can be core layers and/or
clad layers in
clad products. The aluminum alloys and aluminum alloy products possess a
combination of
high formability, high strength, age-hardenability, and allow for the use of
recycled materials
in their formation. The inventors surprisingly discovered that highly formable
alloys can be
prepared using aluminum alloys, for example a 5xxx series aluminum alloy with
relatively
low Mg content or a 6xxx series aluminum alloy with a relatively high Mg
content, for
example from about 1.0 wt. % to about 1.6 wt. % Mg, and about 0.2 wt. % to
about 0.5 wt. %
Si. Without being bound by theory, it is believed that using the described Mg
amounts can
lead to an increase in Si solubility. Thus, by also adjusting the Si
concentrations, the insoluble
phases are avoided and the age hardening potential of the alloys can be
increased. Again,
without being bound by theory, the Mg concentrations can provide solution
hardening, while
the Si concentrations can provide precipitation hardening.
[0017] In some aspects, the aluminum alloy can comprise Mg in an amount up
to about
1.6 wt. %. In terms of ranges, the aluminum alloy can comprise from about 0.50
wt. % to
about 1.6 wt. % Mg. In some aspects, the aluminum alloy can comprise at least
about 0.20
-3-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
wt. % Si. For example, the aluminum alloy can comprise from about 0.20 wt. %
to about 0.50
wt. % Si.
[0018] Thus, in some aspects, the aluminum alloy can comprise from about
0.50 wt. % to
about 1.6 wt. % Mg, and from about 0.20 wt. % to about 0.50 wt. % Si. In some
aspects, the
ratio of Mg wt. % to wt. % Si in the aluminum alloy can be from about 10:1 to
about 1:1
(e.g., about 10:1 to about 1.5:1; about 10:1 to about 2:1; about 9:1 to about
2:1; about 7:1 to
about 2:1; about 5:1 to about 2:1; about 4:1 to about 2:1; or about 3:1 to
about 2:1).
[0019] Unexpectedly, the aluminum alloys described herein exhibit both high
formability
and age hardening. The aluminum alloys described herein also demonstrate good
tensile
properties, bendability, and deep-drawability.
[0020] The high formability can be measured, for example, by measuring
total elongation
or uniform elongation. ISO/EN A80 is one appropriate standard that can be used
for testing
the total elongation (EN 10002 parts 1-5, (2001)). ISO/EN Ag is one
appropriate standard
that can be used for testing the uniform elongation. For example, the aluminum
alloys as
described can have a total elongation (A80) in any direction or all directions
(longitudinal
(L), diagonal (D), and/or transverse (T)) of at least about 20 % (e.g., from
about 20 % to
about 40 %). In some examples, the aluminum alloys as described can have a
uniform
elongation (Ag) in any direction or all directions (longitudinal (L), diagonal
(D), and/or
transverse (T)) of at least about 18 % (e.g., from about 18 % to about 30 %).
[0021] Another way to measure formability is the r value (also known as the
Lankford
coefficient), the plastic strain ratio during a tensile test. The r value is a
measurement of the
deep-drawability of a sheet metal (i.e., the resistance of a material to
thinning or thickening
when put into tension or compression). The r value can be measured according
to ISO 10113
(2006) or according to ASTM E517 (2019), for example. The r value measured
over a strain
range from 10 % to 15 % is indicated as r (10-15). For instance, the aluminum
alloys as
described can have an r (10-15) value in any direction or all directions
(longitudinal (L),
diagonal (D), and/or transverse (T)) of at least about 0.45 (e.g., from about
0.45 to about
0.80).
[0022] The n value, or the strain hardening exponent, gives an indication
of how much
the material hardens or becomes stronger when plastically deformed. The n
value can be
measured using ISO 10275 (2007) or according to ASTM E646 (2016), for example.
The n
value measured over a strain range from 10% to 20% is indicated as n (10-20).
For instance,
the aluminum alloys as described can have an n (10-20) value in any individual
direction or
-4-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
in all directions (longitudinal (L), diagonal (D), and/or transverse (T)) of
at least about 0.20
(e.g., from about 0.20 to about 0.30).
[0023] Age hardening can be tested by measuring the bake hardening value in
MPa, for
example. For example, the aluminum alloys as described can have a bake
hardening value
from about 70 MPa to about 140 MPa.
[0024] Bending can be determined by measuring the f-factor. For example,
the aluminum
alloys as described can have an f-factor at 10% elongation of less than about
0.85 (e.g., from
about 0.30 to about 0.80).
[0025] Surprisingly, the aluminum alloys as described herein are age-
hardenable while
still exhibiting high formability, including deep-drawability and bendability.
For example, the
aluminum alloys described herein can, in some aspects, have yield strengths
(Rp0.2) after
bake hardening of up to about 230 MPa (e.g., from about 150 MPa to about 210
MPa).
[0026] Provided herein are materials, such as aluminum alloy products,
comprising the
aluminum alloys described herein. Also provided are materials comprising the
core aluminum
alloy layers described herein. For example, the core aluminum alloy layers can
be combined
with at least one clad layer and used in clad aluminum alloy products. The
aluminum alloys
can also serve as the clad layer in clad aluminum alloy products. The aluminum
alloy
products or the clad aluminum alloy products can include automotive products
(e.g.,
automotive structural parts), aerospace products (e.g., an aerospace
structural part or an
aerospace non-structural part), marine products (e.g., a marine structural
part or a marine
non-structural part), or electronic products (e.g., electronic device
housings), among others.
Further provided are aluminum alloy sheets, plates, and shates comprising an
aluminum alloy
product or a clad aluminum alloy product as described herein.
Definitions and Descriptions:
[0027] As used herein, the terms "invention," "the invention," "this
invention," and "the
present invention" are intended to refer broadly to all of the subject matter
of this patent
application and the claims below. Statements containing these terms should be
understood
not to limit the subject matter described herein or to limit the meaning or
scope of the patent
claims below.
[0028] In this description, reference is made to alloys identified by AA
numbers and
other related designations, such as "series" or "5xxx." For an understanding
of the number
designation system most commonly used in naming and identifying aluminum and
its alloys,
see "International Alloy Designations and Chemical Composition Limits for
Wrought
-5-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
Aluminum and Wrought Aluminum Alloys" or "Registration Record of Aluminum
Association Alloy Designations and Chemical Compositions Limits for Aluminum
Alloys in
the Form of Castings and Ingot," both published by The Aluminum Association.
[0029] As used herein, a plate generally has a thickness of greater than
about 15 mm. For
example, a plate may refer to an aluminum product having a thickness of
greater than 15 mm,
greater than 20 mm, greater than 25 mm, greater than 30 mm, greater than 35
mm, greater
than 40 mm, greater than 45 mm, greater than 50 mm, or greater than 100 mm.
[0030] As used herein, a shate (also referred to as a sheet plate)
generally has a thickness
of from about 4 mm to about 15 mm. For example, a shate may have a thickness
of 4 mm, 5
mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, or 15 mm.
[0031] As used herein, a sheet generally refers to an aluminum product
having a
thickness of less than about 4 mm. For example, a sheet may have a thickness
of less than 4
mm, less than 3 mm, less than 2 mm, less than 1 mm, less than 0.5 mm, less
than 0.3 mm, or
less than 0.1 mm.
[0032] Reference is made in this application to alloy temper or condition.
For an
understanding of the alloy temper descriptions most commonly used, see
"American National
Standards (ANSI) H35 on Alloy and Temper Designation Systems." An F condition
or
temper refers to an aluminum alloy as fabricated. A W condition or temper
refers to an
aluminum alloy solution heat treated at a temperature greater than a solvus
temperature of the
aluminum alloy and then quenched. An 0 condition or temper refers to an
aluminum alloy
after annealing. An Hxx condition or temper, also referred to herein as an H
temper, refers to
a non-heat treatable aluminum alloy after cold rolling with or without thermal
treatment (e.g.,
annealing). Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8,
or
HX9 tempers. A Ti condition or temper refers to an aluminum alloy cooled from
hot working
and naturally aged (e.g., at room temperature). A T2 condition or temper
refers to an
aluminum alloy cooled from hot working, cold worked and naturally aged. A T3
condition or
temper refers to an aluminum alloy solution heat treated, cold worked, and
naturally aged. A
T4 condition or temper refers to an aluminum alloy solution heat treated and
naturally aged.
A T5 condition or temper refers to an aluminum alloy cooled from hot working
and
artificially aged (at elevated temperatures). A T6 condition or temper refers
to an aluminum
alloy solution heat treated and artificially aged. A T7 condition or temper
refers to an
aluminum alloy solution heat treated and artificially overaged. A T8x
condition or temper
refers to an aluminum alloy solution heat treated, cold worked, and
artificially aged. A T9
-6-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
condition or temper refers to an aluminum alloy solution heat treated,
artificially aged, and
cold worked.
[0033] As used herein, terms such as "cast metal product," "cast product,"
"cast
aluminum alloy product," and the like are interchangeable and refer to a
product produced by
direct chill casting (including direct chill co-casting) or semi-continuous
casting, continuous
casting (including, for example, by use of a twin belt caster, a twin roll
caster, a block caster,
or any other continuous caster), electromagnetic casting, hot top casting, or
any other casting
method.
[0034] As used herein, the meaning of "room temperature" can include a
temperature of
from about 15 C to about 30 C, for example about 15 C, about 16 C, about
17 C, about
18 C, about 19 C, about 20 C, about 21 C, about 22 C, about 23 C, about
24 C, about
25 C, about 26 C, about 27 C, about 28 C, about 29 C, or about 30 C. As
used herein,
the meaning of "ambient conditions" can include temperatures of about room
temperature,
relative humidity of from about 20 % to about 100 %, and barometric pressure
of from about
975 millibar (mbar) to about 1050 mbar. For example, relative humidity can be
about 20 %,
about 21 %, about 22 %, about 23 %, about 24 %, about 25 %, about 26 %, about
27 %, about
28 %, about 29 %, about 30 %, about 31 %, about 32 %, about 33 %, about 34 %,
about 35
%, about 36 %, about 37 %, about 38 %, about 39 %, about 40 %, about 41 %,
about 42 %,
about 43 %, about 44 %, about 45 %, about 46 %, about 47 %, about 48 %, about
49 %, about
50 %, about 51 %, about 52 %, about 53 %, about 54 %, about 55 %, about 56 %,
about 57
%, about 58 %, about 59 %, about 60 %, about 61 %, about 62 %, about 63 %,
about 64 %,
about 65 %, about 66 %, about 67 %, about 68 %, about 69 %, about 70 %, about
71 %, about
72 %, about 73 %, about 74 %, about 75 %, about 76 %, about 77 %, about 78 %,
about 79
%, about 80 %, about 81 %, about 82%, about 83 %, about 84 %, about 85 %,
about 86 %,
about 87 %, about 88 %, about 89 %, about 90 %, about 91 %, about 92 %, about
93 %, about
94 %, about 95 %, about 96 %, about 97 %, about 98 %, about 99 %, about 100 %,
or
anywhere in between. For example, barometric pressure can be about 975 mbar,
about 980
mbar, about 985 mbar, about 990 mbar, about 995 mbar, about 1000 mbar, about
1005 mbar,
about 1010 mbar, about 1015 mbar, about 1020 mbar, about 1025 mbar, about 1030
mbar,
about 1035 mbar, about 1040 mbar, about 1045 mbar, about 1050 mbar, or
anywhere in
between.
[0035] All ranges disclosed herein are to be understood to encompass any
and all
subranges subsumed therein. For example, a stated range of "1 to 10" should be
considered to
include any and all subranges between (and inclusive of) the minimum value of
1 and the
-7-

CA 03126851 2021-07-14
WO 2020/185920
PCT/US2020/022133
maximum value of 10; that is, all subranges beginning with a minimum value of
1 or more,
e.g. 1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10.
The term
"about" includes the exact value.
[0036] As used herein, the meaning of "a," "an," and "the" includes
singular and plural
references unless the context clearly dictates otherwise.
[0037] As used herein, "clad layer," "cladding layer," or "clad aluminum
alloy layer"
refers to a material that is or will be used as a cladding on a core layer. A
"core layer" or
"core aluminum alloy layer" refers to the inner material that can be the major
component in a
clad product (e.g., at least 50 % or more of the clad product). A "clad
product" or "clad
aluminum alloy product" refers to the combination of at least one clad layer
on a core layer.
[0038] As used herein, used beverage cans (UBC) refers to any used beverage
can scrap
known in the art, for example those described in the Scrap Specifications
Circular (2018)
published by the Institute of Scrap Recycling Industries, Inc., including
shredded aluminum
UBC scrap, densified aluminum UBC scrap, baled aluminum UBC scrap, and/or
briquetted
aluminum UBC scrap.
[0039] Throughout the application, the aluminum alloys and aluminum alloy
products
and their components are described in terms of their elemental composition in
weight percent
(wt. %). In some aspects, the remainder for the alloy is aluminum, with a
maximum wt. % of
0.50 % for the sum of all impurities (e.g., a maximum of 0.45 wt. %, a maximum
of 0.40 wt.
%, a maximum of 0.35 wt. %, a maximum of 0.30 wt. %, a maximum of 0.25 wt. %,
a
maximum of 0.20 wt. %, a maximum of 0.15 wt. %, and/or a maximum of 0.10 wt.
%).
New Aluminum Alloys
[0040] The aluminum alloys as described herein are aluminum alloys
comprising Mg and
Si. The aluminum alloys can further optionally comprise Fe, Cu, Mn, Cr, Zn,
Ti, other
elements (e.g., impurities) and combinations thereof.
[0041] In some aspects, the aluminum alloy can comprise up to about 1.60
wt. % Mg,
e.g., up to about 1.58 wt. % Mg, up to about 1.56 wt. % Mg, up to about 1.54
wt. % Mg, up
to about 1.52 wt. % Mg, up to about 1.50 wt. % Mg, up to about 1.48 wt. % Mg,
up to about
1.46 wt. % Mg, up to about 1.45 wt. % Mg, up to about 1.43 wt. % Mg, up to
about 1.42 wt.
% Mg, up to about 1.40 wt. % Mg, up to about 1.38 wt. % Mg, up to about 1.37
wt. % Mg,
up to about 1.35 wt. % Mg, up to about 1.33 wt. % Mg, up to about 1.32 wt. %
Mg, up to
about 1.30 wt. % Mg, up to about 1.28 wt. % Mg, up to about 1.27 wt. % Mg, up
to about
1.25 wt. % Mg, up to about 1.23 wt. % Mg, up to about 1.22 wt. % Mg, up to
about 1.20 wt.
-8-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
% Mg, up to about 1.18 wt. % Mg, up to about 1.17 wt. % Mg, up to about 1.15
wt. % Mg,
up to about 1.13 wt. % Mg, up to about 1.12 wt. % Mg, up to about 1.10 wt. %
Mg, up to
about 1.08 wt. % Mg, up to about 1.07 wt. % Mg, up to about 1.05 wt. % Mg, up
to about
1.03 wt. % Mg, up to about 1.02 wt. % Mg, up to about 1.00 wt. % Mg, up to
about 0.95 wt.
% Mg, up to about 0.90 wt. % Mg, up to about 0.85 wt. % Mg, up to about 0.80
wt. % Mg,
up to about 0.75 wt. % Mg, up to about 0.70 wt. % Mg, up to about 0.65 wt. %
Mg, up to
about 0.60 wt. % Mg, up to about 0.55 wt. % Mg, or up to about 0.50 wt. % Mg.
In terms of
ranges, the aluminum alloy can comprise from about 0.50 wt. % to about 1.60
wt. % Mg, e.g.,
from about 0.60 wt. % to about 1.55 wt. % Mg, from about 0.70 wt. % to about
1.52 wt. %
Mg, from about 0.80 wt. % to about 1.50 wt. % Mg, from about 0.90 wt. % to
about 1.50 wt.
% Mg, from about 1.00 wt. % to about 1.50 wt. % Mg, from about 1.10 wt. % to
about 1.50
wt. % Mg, from about 1.20 wt. % to about 1.50 wt. % Mg, or from about 1.30 wt.
% to about
1.50 wt. % Mg.
[0042] In some aspects, the aluminum alloy can comprise up to about 0.50
wt. % Si, e.g.,
up to about 0.49 wt. % Si, up to about 0.48 wt. % Si, up to about 0.47 wt. %
Si, up to about
0.46 wt. % Si, up to about 0.45 wt. % Si, up to about 0.44 wt. % Si, up to
about 0.43 wt. %
Si, up to about 0.42 wt. % Si, up to about 0.41 wt. % Si, up to about 0.40 wt.
% Si, up to
about 0.39 wt. % Si, up to about 0.38 wt. % Si, up to about 0.37 wt. % Si, up
to about 0.36
wt. % Si, up to about 0.35 wt. % Si, up to about 0.34 wt. % Si, up to about
0.33 wt. % Si, up
to about 0.32 wt. % Si, up to about 0.31 wt. % Si, up to about 0.30 wt. % Si,
up to about 0.29
wt. % Si, up to about 0.28 wt. % Si, up to about 0.27 wt. % Si, up to about
0.26 wt. % Si, up
to about 0.25 wt. % Si, up to about 0.24 wt. % Si, up to about 0.23 wt. % Si,
up to about 0.22
wt. % Si, up to about 0.21 wt. % Si, up to about 0.20 wt. % Si, up to about
0.19 wt. % Si, up
to about 0.18 wt. % Si, up to about 0.17 wt. % Si, up to about 0.16 wt. % Si,
or up to about
0.15 wt. % Si.
[0043] In some aspects, the aluminum alloy can comprise at least about 0.15
wt. % Si, at
least about 0.16 wt. % Si, at least about 0.17 wt. % Si, at least about 0.18
wt. % Si, at least
about 0.19 wt. % Si, at least about 0.20 wt. % Si, at least about 0.21 wt. %
Si, at least about
0.22 wt. % Si, at least about 0.23 wt. % Si, at least about 0.24 wt. % Si, at
least about 0.25 wt.
% Si, at least about 0.26 wt. % Si, at least about 0.27 wt. % Si, at least
about 0.28 wt. % Si, at
least about 0.29 wt. % Si, at least about 0.30 wt. % Si, at least about 0.31
wt. % Si, at least
about 0.32 wt. % Si, at least about 0.33 wt. % Si, at least about 0.34 wt. %
Si, at least about
0.35 wt. % Si, at least about 0.36 wt. % Si, at least about 0.37 wt. % Si, at
least about 0.38 wt.
% Si, at least about 0.39 wt. % Si, at least about 0.40 wt. % Si, at least
about 0.41 wt. % Si, at
-9-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
least about 0.42 wt. % Si, at least about 0.43 wt. % Si, at least about 0.44
wt. % Si, at least
about 0.45 wt. % Si, at least about 0.46 wt. % Si, at least about 0.47 wt. %
Si, at least about
0.48 wt. % Si, at least about 0.49 wt. % Si, or at least about 0.50 wt. % Si.
[0044] In terms of ranges, the aluminum alloy can comprise from about 0.15
wt. % to
about 0.5 wt. % Si, e.g., from about 0.20 wt. % to about 0.45 wt. % Si, from
about 0.22 wt. %
to about 0.43 wt. % Si, from about 0.25 wt. % to about 0.41 wt. % Si, from
about 0.26 wt. %
to about 0.40 wt. % Si, from about 0.28 wt. % to about 0.40 wt. % Si, from
about 0.30 wt. %
to about 0.40 wt. % Si, from about 0.31 wt. % to about 0.39 wt. % Si, from
about 0.32 wt. %
to about 0.38 wt. % Si, from about 0.33 wt. % to about 0.38 wt. % Si, from
about 0.34 wt. %
to about 0.38 wt. % Si, or from about 0.34 wt. % to about 0.37 wt. % Si.
[0045] Thus, in some aspects, the aluminum alloy can comprise from about
0.50 wt. % to
about 1.5 wt. % Mg and from about 0.15 wt. % to about 0.50 wt. % Si. In some
aspects, the
ratio of Mg wt. % to wt. %Si in the aluminum alloy can be from about 10:1 to
about 1:1 (e.g.,
about 10:1 to about 1.5:1; about 10:1 to about 2:1; about 9:1 to about 1.5:1;
about 9:1 to
about 2:1; about 8:1 to about 1.5:1; about 8:1 to about 2:1; about 7:1 to
about 2:1; about 5:1
to about 2:1; about 4:1 to about 2:1; or about 3:1 to about 2:1).
[0046] The aluminum alloy can optionally comprise up to about 1.0 wt. %
iron (Fe), e.g.,
up to about 0.95 wt. % Fe, up to about 0.90 wt. % Fe, up to about 0.85 wt. %
Fe, up to about
0.80 wt. % Fe, up to about 0.75 wt. % Fe, up to about 0.70 wt. % Fe, up to
about 0.65 wt. %
Fe, up to about 0.60 wt. % Fe, up to about 0.55 wt. % Fe, up to about 0.50 wt.
% Fe, up to
about 0.45 wt. % Fe, up to about 0.40 wt. % Fe, up to about 0.35 wt. % Fe, up
to about 0.30
wt. % Fe, up to about 0.25 wt. % Fe, up to about 0.20 wt. % Fe, up to about
0.15 wt. % Fe, up
to about 0.10 wt. % Fe, up to about 0.08 wt. % Fe, up to about 0.05 wt. % Fe,
up to about
0.03 wt. % Fe, or up to about 0.01 wt. % Fe. In terms of ranges, the aluminum
alloy can
optionally comprise from about 0.01 wt. % to about 1.0 wt. % Fe, e.g., from
about 0.03 wt. %
to about 0.90 wt. % Fe, from about 0.05 wt. % to about 0.80 wt. % Fe, from
about 0.08 wt. %
to about 0.80 wt. % Fe, from about 0.08 wt. % to about 0.75 wt. % Fe, from
about 0.01 wt. %
to about 0.70 wt. % Fe, from about 0.20 wt. % to about 0.60 wt. % Fe, from
about 0.20 wt. %
to about 0.55 wt. % Fe, from about 0.25 wt. % to about 0.55 wt. % Fe, from
about 0.25 wt. %
to about 0.50 wt. % Fe, or from about 0.30 wt. % to about 0.50 wt. % Fe.
[0047] The aluminum alloy can optionally comprise copper (Cu). In some
aspects, the
aluminum alloy can comprise up to about 0.5 wt. % Cu, e.g., up to about 0.45
wt. % Cu, up to
about 0.40 wt. % Cu, up to about 0.35 wt. % Cu, up to about 0.30 wt. % Cu, up
to about 0.25
wt. % Cu, up to about 0.20 wt. % Cu, up to about 0.15 wt. % Cu, up to about
0.10 wt. % Cu,
-10-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
up to about 0.05 wt. % Cu, up to about 0.04 wt. % Cu, up to about 0.03 wt. %
Cu, up to about
0.02 wt. % Cu, or up to about 0.01 wt. % Cu. In terms of ranges, the aluminum
alloy can
optionally comprise from about 0.01 wt. % to about 0.5 wt. % Cu, e.g., from
about 0.03 wt.
% to about 0.40 wt. % Cu, from about 0.03 wt. % to about 0.30 wt. % Cu, from
about 0.03
wt. % to about 0.10 wt. % Cu, from about 0.04 wt. % to about 0.08 wt. % Cu, or
from about
0.04 wt. % to about 0.06 wt. % Cu.
[0048] The aluminum alloy can optionally comprise manganese (Mn). In some
aspects,
the aluminum alloy can comprise up to about 0.5 wt. % Mn, e.g., up to about
0.45 wt. % Mn,
up to about 0.40 wt. % Mn, up to about 0.35 wt. % Mn, up to about 0.30 wt. %
Mn, up to
about 0.25 wt. % Mn, up to about 0.20 wt. % Mn, up to about 0.15 wt. % Mn, up
to about
0.10 wt. % Mn, up to about 0.05 wt. % Mn, up to about 0.04 wt. % Mn, up to
about 0.03 wt.
% Mn, up to about 0.02 wt. % Mn, or up to about 0.01 wt. % Mn. In terms of
ranges, the
aluminum alloy can optionally comprise from about 0.01 wt. % to about 0.5 wt.
% Mn, e.g.,
from about 0.03 wt. % to about 0.40 wt. % Mn, from about 0.03 wt. % to about
0.30 wt. %
Mn, from about 0.03 wt. % to about 0.25 wt. % Mn, from about 0.04 wt. % to
about 0.20 wt.
% Mn, or from about 0.10 wt. % to about 0.20 wt. % Mn.
[0049] The aluminum alloy can optionally comprise chromium (Cr). In some
aspects, the
aluminum alloy can comprise up to about 0.3 wt. % Cr, e.g., up to about 0.25
wt. % Cr, up to
about 0.20 wt. % Cr, up to about 0.15 wt. % Cr, up to about 0.10 wt. % Cr, up
to about 0.08
wt. % Cr, up to about 0.05 wt. % Cr, up to about 0.03 wt. % Cr, up to about
0.02 wt. % Cr, up
to about 0.01 wt. % Cr, or up to about 0.008 wt. % Cr. In terms of ranges, the
aluminum alloy
can optionally comprise from about 0.005 wt. % to about 0.30 wt. % Cr, e.g.,
from about
0.008 wt. % to about 0.30 wt. % Cr, from about 0.01 wt. % to about 0.30 wt. %
Cr, from
about 0.03 wt. % to about 0.25 wt. % Cr, from about 0.05 wt. % to about 0.25
wt. % Cr, from
about 0.06 wt. % to about 0.20 wt. % Cr, or from about 0.08 wt. % to about
0.15 wt. % Cr.
[0050] The aluminum alloy can optionally comprise titanium (Ti). In some
aspects, the
aluminum alloy can comprise up to about 0.3 wt. % Ti, e.g., up to about 0.25
wt. % Ti, up to
about 0.20 wt. % Ti, up to about 0.15 wt. % Ti, up to about 0.10 wt. % Ti, up
to about 0.08
wt. % Ti, up to about 0.05 wt. % Ti, up to about 0.03 wt. % Ti, up to about
0.02 wt. % Ti, up
to about 0.01 wt. % Ti, or up to about 0.008 wt. % Ti. In terms of ranges, the
aluminum alloy
can optionally comprise from about 0.005 wt. % to about 0.30 wt. % Ti, e.g.,
from about
0.008 wt. % to about 0.30 wt. % Ti, from about 0.01 wt. % to about 0.30 wt. %
Ti, from
about 0.03 wt. % to about 0.25 wt. % Ti, from about 0.05 wt. % to about 0.25
wt. % Ti, from
about 0.06 wt. % to about 0.20 wt. % Ti, or from about 0.08 wt. % to about
0.15 wt. % Ti.
-11-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
[0051] The aluminum alloy can optionally comprise zinc (Zn). In some
aspects, the
aluminum alloy can comprise up to about 0.5 wt. % Zn, e.g., up to about 0.45
wt. % Zn, up to
about 0.40 wt. % Zn, up to about 0.35 wt. % Zn, up to about 0.30 wt. % Zn, up
to about 0.25
wt. % Zn, up to about 0.20 wt. % Zn, up to about 0.15 wt. % Zn, up to about
0.10 wt. % Zn,
up to about 0.08 wt. % Zn, up to about 0.05 wt. % Zn, up to about 0.03 wt. %
Zn, up to about
0.02 wt. % Zn, up to about 0.01 wt. % Zn, or up to about 0.008 wt. % Zn. In
terms of ranges,
the aluminum alloy can optionally comprise from about 0.005 wt. % to about
0.50 wt. % Zn,
e.g., from about 0.008 wt. % to about 0.30 wt. % Zn, from about 0.01 wt. % to
about 0.30 wt.
% Zn, from about 0.03 wt. % to about 0.25 wt. % Zn, from about 0.05 wt. % to
about 0.25
wt. % Zn, from about 0.06 wt. % to about 0.20 wt. % Zn, or from about 0.08 wt.
% to about
0.15 wt. % Zn.
[0052] Optionally, the aluminum alloy described herein can further include
other minor
elements, sometimes referred to as impurities, in amounts of about 0.05 wt. %
or below,
about 0.04 wt. % or below, about 0.03 wt. % or below, about 0.02 wt. % or
below, or about
0.01 wt. % or below. These impurities may include, but are not limited to, V,
Ni, Sc, Hf, Zr,
Sn, Ga, Bi, Na, Pb, or combinations thereof. Accordingly, V, Ni, Sc, Hf, Zr,
Sn, Ga, Bi, Na,
or Pb, may each be present in the alloys in amounts of about 0.05 wt. % or
below, about 0.04
wt. % or below, about 0.03 wt. % or below, about 0.02 wt. % or below, or about
0.01 wt. %
or below, for example. The sum of all impurities does not exceed about 0.50
wt. % (e.g., does
not exceed about 0.40 wt. %, about 0.30 wt. %, about 0.25 wt. %, about 0.20
wt. % about
0.15 wt. %, or about 0.10 wt. %). All expressed in wt. %. In some aspects, the
remaining
percentage of the alloy is aluminum.
[0053] Optionally, the aluminum alloy can comprise recycled aluminum or
aluminum
alloys. For example, the aluminum alloy can comprise recycled 5xxx series
aluminum alloy
scrap. As another example, the aluminum alloy can comprise recycled 6xxx
series aluminum
alloy scrap or both 5xxx series aluminum alloy scrap and 6xxx series aluminum
alloy scrap.
Recycled aluminum content, recycled aluminum, or recycled aluminum scrap as
used herein
refers to any aluminum and/or aluminum alloy that is reused or recovered from
a prior use.
Recycled aluminum content can include, but is broader than used beverage cans
content. In
some aspects, the aluminum alloy can contain at least about 10 wt. % recycled
content (e.g.,
at least about 15 wt. % recycled content, at least about 20 wt. % recycled
content, at least
about 25 wt. % recycled content, at least about 30 wt. % recycled content, at
least about 35
wt. % recycled content, at least about 40 wt. % recycled content, at least
about 45 wt. %
recycled content, at least about 50 wt. % recycled content, at least about 55
wt. % recycled
-12-

CA 03126851 2021-07-14
WO 2020/185920
PCT/US2020/022133
content, or at least about 60 wt. % recycled content). In some aspects, the
aluminum alloy can
contain at least about 5 % used beverage cans ("UBC") (e.g., at least about 8
wt. % UBC, at
least about 10 wt. % UBC, at least about 15 wt. % UBC, at least about 20 wt. %
UBC, at least
about 25 wt. % UBC, at least about 30 wt. % UBC, at least about 35 wt. % UBC,
at least
about 40 wt. % UBC, at least about 45 wt. % UBC, at least about 50 wt. % UBC,
at least
about 55 wt. % UBC, or at least about 60 wt. % UBC) UBC scrap as used herein
is collected
metal from used beverage cans and similar products that can be recycled for
use in further
metal products. Aluminum UBC scrap is often a mixture of various aluminum
alloys (e.g.,
from different alloys used for can bodies and can ends) and can often include
foreign
substances, such as rainwater, drink remainders, organic matter (e.g., paints
and laminated
films), and other materials. UBC scrap generally contains a mixture of metal
from various
alloys, such as metal from can bodies (e.g., 3104, 3004, or other 3xxx
aluminum alloy) and
can ends (e.g., 5182 or other 5xxx aluminum alloy). UBC scrap can be shredded
and
decoated or delacquered prior to being melted for use as liquid metal stock in
casting a new
metal product.
[0054] In
some aspects, the aluminum alloy can comprise a combined concentration of
Fe, Cu, and Mn of greater than about 0.5 wt. %, (e.g., greater than about 0.6
wt. %, greater
than about 0.7 wt. %, greater than about 0.8 wt. %, greater than about 0.9 wt.
%, greater than
about 1.0 wt. %, greater than about 1.2 wt. %, greater than about 1.5 wt. %,
greater than
about 1.7 wt. %, greater than about 2.0 wt. %, greater than about 2.2 wt. %,
greater than
about 2.5 wt. %, greater than about 2.7 wt. %, greater than about 3.0 wt. %,
from about 0.5
wt. % to about 3.0 wt. %, from about 0.5 wt. % to about 2.8 wt. %, from about
0.6 wt. % to
about 2.5 wt. %, from about 0.7 wt. % to about 2.5 wt. %, from about 0.7 wt. %
to about 2.2
wt. %, from about 0.9 wt. % to about 3.0 wt. %, or from about 1.0 wt. % to
about 2.0 wt. %).
As indicated, in other aspects, Fe, Cu, and Mn are not present or may be
present at lower
levels.
[0055] The
aluminum alloys as described herein can have an average grain diameter of
from about 5 p.m to about 50 p.m (e.g., from about 8 p.m to about 40 p.m, from
about 10 p.m to
about 30 p.m, or from about 15 p.m to about 25 pm), for example. In some
aspects, the grain
sizes of the aluminum alloys described are suitable for skin applications.
-13-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
Properties of New Aluminum Alloys
[0056] The aluminum alloys described herein surprisingly exhibit both high
formability
and age hardening. The aluminum alloys described herein also demonstrate good
tensile
properties, bendability, and deep-drawability.
[0057] For example, the aluminum alloys described herein can, in some
aspects, have
yield strengths (Rp0.2) after bake hardening (e.g., after a paint bake cycle
of 20 minutes at
185 C to a T8x temper) of up to about 250 MPa (e.g., from about 80 MPa to
about 240 MPa,
from about 150 MPa to about 230 MPa, from about 160 MPa to about 230 MPa, from
about
165 MPa to about 220 MPa, or from about 170 MPa to about 210 MPa). Rp0.2
refers to the
amount of stress that will result in a plastic strain of 0.2 %. In some
examples, the yield
strengths (Rp0.2) of the aluminum alloys can be about 100 MPa, about 110 MPa,
about 120
MPa, about 130 MPa, about 140 MPa, about 150 MPa, about 160 MPa, about 170
MPa,
about 180 MPa, about 190 MPa, about 200 MPa, about 210 MPa, about 220 MPa,
about 230
MPa, or about 240 MPa. Further, in some aspects, the aluminum alloys described
herein can
have an ultimate tensile strength (Rm) after bake hardening (e.g., after a
paint bake cycle of
20 minutes at 185 C to a T8x temper) of up to about 300 MPa (e.g., from about
230 MPa to
about 300 MPa, from about 240 MPa to about 300 MPa, or from about 240 MPa to
about 290
MPa). Rm refers to the ultimate tensile strength. Thus in some examples, the
Rm of the
aluminum alloys can be about 230 MPa, about 240 MPa, about 250 MPa, about 260
MPa,
about 270 MPa, about 280 MPa, about 290 MPa, or about 300 MPa.
[0058] In some aspects, the aluminum alloys as described herein can have a
yield strength
(Rp0.2) before bake hardening (T4 temper) of from about 80 MPa to about 140
MPa (e.g.,
from about 80 MPa to about 130 MPa, from about 80 MPa to about 120 MPa, or
from about
85 MPa to about 110 MPa). Further, the aluminum alloys as described herein can
have an Rm
before bake hardening (T4 temper) of from about 170 MPa to about 280 MPa
(e.g., from
about 180 MPa to about 270 MPa, from about 170 MPa to about 250 MPa, from
about 190
MPa to about 230 MPa, or from about 190 MPa to about 220 MPa).
[0059] While being age-hardenable, surprisingly, the aluminum alloys as
described
herein still exhibit high formability, including deep-drawability and
bendability.
[0060] For example, the aluminum alloys as described herein can have a
total elongation
(as measured by ISO/EN A80) in any individual direction or in all directions
(longitudinal
(L), diagonal (D), and/or transverse (T)) of at least about 20 % (e.g., at
least about 21 %, at
least about 22 %, at least about 23 %, at least about 24 %, at least about 25
%, at least about
26 %, at least about 27 %, at least about 28 %, at least about 29 %, at least
about 30 %, at
-14-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
least about 31 %, at least about 32 %, at least about 33 %, at least about 34
%, at least about
35 %, at least about 36 %, at least about 37 %, at least about 38 %, at least
about 39 %, or at
least about 40 %). In terms of ranges, the aluminum alloys can have an
elongation of from
about 20 % to about 40 % (e.g., from about 22 % to about 38 %, from about 23 %
to about 36
%, from about 24 % to about 34 %, from about 25 % to about 33 %, from about 25
% to
about 32 %, from about 25 % to about 31 %, from about 25 % to about 30 %, or
from about
25 % to about 29 %).
[0061] In some aspects, the aluminum alloys as described herein can have a
uniform
elongation (Ag) (as measured by ISO/EN Ag) in any individual direction or in
all directions
(longitudinal (L), diagonal (D), and/or transverse (T)) of at least about 18 %
(e.g., at least
about 19 %, at least about 20 %, at least about 21 %, at least about 22 %, at
least about 23 %,
at least about 24 %, at least about 25 %, at least about 26 %, at least about
27 %, at least
about 28 %, at least about 29 %, or at least about 30 %). In terms of ranges,
the aluminum
alloys can have an elongation of from about 18 % to about 30 % (e.g., from
about 22 % to
about 38 %, from about 23 % to about 36 %, from about 24 % to about 34 %, from
about 25
% to about 33 %, from about 25 % to about 32 %, from about 25 % to about 31 %,
from
about 25 % to about 30 %, or from about 25 % to about 29 %).
[0062] In some aspects, the aluminum alloys as described can have an r (10-
15) value in
any individual direction or in all directions (longitudinal (L), diagonal (D),
and/or transverse
(T)) of at least about 0.45 (e.g., of at least about 0.46, of at least about
0.47, of at least about
0.48, of at least about 0.49, of at least about 0.50, of at least about 0.51,
of at least about 0.52,
of at least about 0.53, of at least about 0.54, of at least about 0.55, of at
least about 0.56, of at
least about 0.57, of at least about 0.58, of at least about 0.59, of at least
about 0.60, of at least
about 0.61, of at least about 0.62, of at least about 0.63, of at least about
0.64, of at least
about 0.65, of at least about 0.66, of at least about 0.67, of at least about
0.68, of at least
about 0.69, of at least about 0.70, of at least about 0.71, of at least about
0.72, of at least
about 0.73, of at least about 0.74, of at least about 0.75, of at least about
0.76, of at least
about 0.77, of at least about 0.78, of at least about 0.79, or of at least
about 0.80). In terms of
ranges, the aluminum alloy can have an r (10-15) value in any direction or all
directions
(longitudinal (L), diagonal (D), and/or transverse (T)) of from about 0.45 to
about 0.80 (e.g.,
from about 0.45 to about 0.75, from about 0.47 to about 0.72, from about 0.50
to about 0.70,
or from about 0.52 to about 0.68).
[0063] In some aspects, the aluminum alloys as described can have an n (10-
20) value in
any direction or all directions (longitudinal (L), diagonal (D), and/or
transverse (T)) of at
-15-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
least about 0.20 (e.g., of at least about 0.21, of at least about 0.22, of at
least about 0.23, of at
least about 0.24, of at least about 0.25, of at least about 0.26, of at least
about 0.27, of at least
about 0.28, of at least about 0.29, or of at least about 0.30). In terms of
ranges, the aluminum
alloy can have an n (10-20) value in any individual direction or in all
directions (longitudinal
(L), diagonal (D), and/or transverse (T)) of from about 0.20 to about 0.30
(e.g., of from about
0.21 to about 0.29 or of from about 0.22 to about 0.28).
[0064] Further, the aluminum alloys described herein can have strong
bendability
properties. In some aspects, the aluminum alloys as described can have a
minimum R/t ratio
or f-factor at 10% elongation of about 0.60 or less, for example. As
described, the bendability
is assessed based on the R/t ratio, where R is the radius of the tool (die)
used and t is the
thickness of the material. A lower R/t ratio indicates better bendability of
the material.
[0065] More specifically, the aluminum alloys as described can have an f-
factor at 10%
elongation of less than about 0.85 (e.g., less than about 0.80, less than
about 0.75, less than
about 0.70, less than about 0.65, less than about 0.60, less than about 0.59,
less than about
0.58, less than about 0.57, less than about 0.56, less than about 0.55, less
than about 0.54, less
than about 0.53, less than about 0.52, less than about 0.51, less than about
0.50, less than
about 0.49, less than about 0.48, less than about 0.47, less than about 0.46,
less than about
0.45, less than about 0.44, less than about 0.43, less than about 0.42, less
than about 0.41, less
than about 0.40, less than about 0.39, less than about 0.38, less than about
0.37, less than
about 0.36, less than about 0.35, less than about 0.34, less than about 0.33,
less than about
0.32, less than about 0.31, or less than about 0.30). In terms of ranges, the
aluminum alloys
can have an f-factor at 10% elongation of from about 0.30 to about 0.85 (e.g.,
from about
0.30 to 0.80, from about 0.30 to about 0.75, from about 0.30 to about 0.70,
from about 0.30 to
about 0.65, from about 0.35 to about 0.58, from about 0.35 to about 0.55, from
about 0.35 to
about 0.50, from about 0.35 to about 0.45, or from about 0.37 to about 0.45).
Clad Products
[0066] In addition to monolithic aluminum alloy products, in some aspects,
the aluminum
alloys described here can be used in clad aluminum alloy products. The clad
aluminum alloy
products can comprise the aluminum alloys described as a core layer. In
addition, one or
more clad layers can be in contact with the core layer. In some aspects, the
aluminum alloys
described can serve as a clad layer. In some examples, the core aluminum alloy
layer has a
clad layer on only one side (i.e., one clad layer is present in the clad
aluminum alloy product).
In other examples, the core aluminum alloy layer is cladded on more than one
side, for
-16-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
example both sides (i.e., two clad layers are present in the clad aluminum
alloy product).
Typically, the core layer is the larger component of the material, and
therefore usually
predominately determines the bulk mechanical properties of the clad product,
for example the
strength of the clad product. On the other hand, the clad layer(s), which
typically (but not
always) represent a smaller component of the clad product, are in contact with
the
surrounding environment and thus determine the chemical activity (e.g.,
corrosion resistance)
and can affect the formability and joining properties of the clad product.
[0067] In some aspects, a first side of the core aluminum alloy layer is
adjacent to and
contacts a first clad layer to form a first interface. In other words, no
layers intervene between
the first clad layer and the first side of the core layer. In some aspects,
the clad aluminum
alloy product includes a second clad layer. In some instances, a second side
of the core layer
is adjacent to and contacts the second clad layer to form a second interface
(i.e., no layers
intervene between the second clad layer and the second side of the core
layer). In some
aspects, the first clad layer and the second clad layer can be the same
chemical composition.
In other aspects, the first clad layer and the second clad layer can be
different chemical
compositions.
[0068] In some aspects, the thickness of the clad products can be from
about 0.1 mm to
about 6 mm, (e.g., about 0.1 mm to about 5.8 mm, from about 0.2 mm to about
5.5 mm, from
about 0.3 mm to about 5.3 mm, from about 0.4 mm to about 5.2 mm, from about
0.5 mm to
about 5.0 mm, from about 0.6 mm to about 4.8 mm, from about 0.7 mm to about
4.6 mm,
from about 0.8 mm to about 4.5 mm, from about 0.8 mm to about 4.3 mm, from
about 0.9
mm to about 4.2 mm, from about 1 mm to about 4 mm, from about 1.3 mm to about
3.8 mm,
from about 1.5 mm to about 3.5 mm, from about 1.7 mm to about 3.2 mm, or from
about 2
mm to about 3 mm).
Core Layer
[0069] As noted, the core layer can comprise the aluminum alloys described
above. For
example, the core layer can comprise an aluminum alloy comprising Mg in an
amount from
about 0.50 wt. % to about 1.6 wt. % and Si in an amount from about 0.2 wt. %
to about 0.5
wt. %.
[0070] The thickness of the core layer can be from about 30 % to about 99 %
of the
thickness of the clad aluminum alloy products described herein, e.g., from
about 40 % to 99
%, from about 50 % to 99 %, from about 55 % to 99 %, from about 60 % to 98 %,
from about
70 % to 98 %, from about 75 % to 95 %, or from about 80 % to 90 %. For
example, in a clad
-17-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
aluminum alloy product having a thickness of about 1000 microns, the core
layer can have a
thickness of about 300 microns to about 990 microns. Optionally, the core
layer can have a
thickness in the range of about 0.1 mm to about 5 mm (e.g., about 0.5 mm to
about 3 mm,
from about 0.7 mm to about 2.5 mm, or about 0.8 mm to about 2 mm). For
example, the
thickness of the core layer can be about 0.5 mm, about 0.6 mm, about 0.7 mm,
about 0.8 mm,
about 0.9 mm, about 1.0 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about
1.4 mm,
about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about
2.0 mm,
about 2.1 mm, about 2.2 mm, about 2.3 mm, about 2.4 mm, about 2.5 mm, about
2.6 mm,
about 2.7 mm, about 2.8 mm, about 2.9 mm, or about 3.0 mm.
Clad Layer(s)
[0071] The clad layer(s) of the clad aluminum alloy products can comprise
an aluminum
alloy. In some aspects, the aluminum alloys described herein can serve as the
clad layers(s).
In some examples, any alloy designated as a lxxx series aluminum alloy, a 2xxx
series
aluminum alloy, a 3xxx series aluminum alloy, a 4xxx series aluminum alloy, a
5xxx series
aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum alloy, or
an 8xxx
series aluminum alloy is suitable for use as the clad layer.
[0072] By way of non-limiting example, exemplary lxxx series aluminum
alloys for use
as a clad layer can include AA1100, AA1100A, AA1200, AA1200A, AA1300, AA1110,
AA1120, AA1230, AA1230A, AA1235, AA1435, AA1145, AA1345, AA1445, AA1150,
AA1350, AA1350A, AA1450, AA1370, AA1275, AA1185, AA1285, AA1385, AA1188,
AA1190, AA1290, AA1193, AA1198, and AA1199.
[0073] Non-limiting exemplary 2xxx series aluminum alloys for use as a clad
layer can
include AA2001, A2002, AA2004, AA2005, AA2006, AA2007, AA2007A, AA2007B,
AA2008, AA2009, AA2010, AA2011, AA2011A, AA2111, AA2111A, AA2111B, AA2012,
AA2013, AA2014, AA2014A, AA2214, AA2015, AA2016, AA2017, AA2017A, AA2117,
AA2018, AA2218, AA2618, AA2618A, AA2219, AA2319, AA2419, AA2519, AA2021,
AA2022, AA2023, AA2024, AA2024A, AA2124, AA2224, AA2224A, AA2324, AA2424,
AA2524, AA2624, AA2724, AA2824, AA2025, AA2026, AA2027, AA2028, AA2028A,
AA2028B, AA2028C, AA2029, AA2030, AA2031, AA2032, AA2034, AA2036, AA2037,
AA2038, AA2039, AA2139, AA2040, AA2041, AA2044, AA2045, AA2050, AA2055,
AA2056, AA2060, AA2065, AA2070, AA2076, AA2090, AA2091, AA2094, AA2095,
AA2195, AA2295, AA2196, AA2296, AA2097, AA2197, AA2297, AA2397, AA2098,
AA2198, AA2099, and AA2199.
-18-

CA 03126851 2021-07-14
WO 2020/185920
PCT/US2020/022133
[0074] Non-
limiting exemplary 3xxx series aluminum alloys for use as a clad layer can
include AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B, AA3203, AA3403,
AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A, AA3105, AA3105A,
AA3105B, AA3007, AA3107, AA3207, AA3207A, AA3307, AA3009, AA3010, AA3110,
AA3011, AA3012, AA3012A, AA3013, AA3014, AA3015, AA3016, AA3017, AA3019,
AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, and AA3065.
[0075] Non-
limiting exemplary 4xxx series aluminum alloys for use as a clad layer can
include AA4045, AA4004, AA4104, AA4006, AA4007, AA4008, AA4009, AA4010,
AA4013, AA4014, AA4015, AA4015A, AA4115, AA4016, AA4017, AA4018, AA4019,
AA4020, AA4021, AA4026, AA4032, AA4043, AA4043A, AA4143, AA4343, AA4643,
AA4943, AA4044, AA4145, AA4145A, AA4046, AA4047, AA4047A, and AA4147.
[0076] Non-
limiting exemplary 5xxx series aluminum alloys for use as a clad layer can
include AA5182, AA5183, AA5005, AA5005A, AA5205, AA5305, AA5505, AA5605,
AA5006, AA5106, AA5010, AA5110, AA5110A, AA5210, AA5310, AA5016, AA5017,
AA5018, AA5018A, AA5019, AA5019A, AA5119, AA5119A, AA5021, AA5022, AA5023,
AA5024, AA5026, AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043,
AA5049, AA5149, AA5249, AA5349, AA5449, AA5449A, AA5050, AA5050A, AA5050C,
AA5150, AA5051, AA5051A, AA5151, AA5251, AA5251A, AA5351, AA5451, AA5052,
AA5252, AA5352, AA5154, AA5154A, AA5154B, AA5154C, AA5254, AA5354, AA5454,
AA5554, AA5654, AA5654A, AA5754, AA5854, AA5954, AA5056, AA5356, AA5356A,
AA5456, AA5456A, AA5456B, AA5556, AA5556A, AA5556B, AA5556C, AA5257,
AA5457, AA5557, AA5657, AA5058, AA5059, AA5070, AA5180, AA5180A, AA5082,
AA5182, AA5083, AA5183, AA5183A, AA5283, AA5283A, AA5283B, AA5383, AA5483,
AA5086, AA5186, AA5087, AA5187, and AA5088.
[0077] Non-
limiting exemplary 6xxx series aluminum alloys for use as a clad layer can
include AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002,
AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305,
AA6006, AA6106, AA6206, AA6306, AA6008, AA6009, AA6010, AA6110, AA6110A,
AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA6016,
AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024,
AA6025, AA6026, AA6027, AA6028, AA6031, AA6032, AA6033, AA6040, AA6041,
AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA6053, AA6055,
AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560,
AA6660, AA6061, AA6061A, AA6261, AA6361, AA6162, AA6262, AA6262A, AA6063,
-19-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
AA6063A, AA6463, AA6463A, AA6763, A6963, AA6064, AA6064A, AA6065, AA6066,
AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6182,
AA6091, and AA6092.
[0078] Non-limiting exemplary 7xxx series aluminum alloys for use as a clad
layer can
include AA7011, AA7019, AA7020, AA7021, AA7039, AA7072, AA7075, AA7085,
AA7108, AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024, AA7025, AA7028,
AA7030, AA7031, AA7033, AA7035, AA7035A, AA7046, AA7046A, AA7003, AA7004,
AA7005, AA7009, AA7010, AA7011, AA7012, AA7014, AA7016, AA7116, AA7122,
AA7023, AA7026, AA7029, AA7129, AA7229, AA7032, AA7033, AA7034, AA7036,
AA7136, AA7037, AA7040, AA7140, AA7041 , AA7049, AA7049A, AA7149, AA7204,
AA7249, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7250, AA7055, AA7155,
AA7255, AA7056, AA7060, AA7064, AA7065, AA7068, AA7168, AA7175, AA7475,
AA7076, AA7178, AA7278, AA7278A, AA7081, AA7181, AA7185, AA7090, AA7093,
AA7095, and AA7099.
[0079] Non-limiting exemplary 8xxx series aluminum alloys suitable for use
as a clad
layer can include AA8005, AA8006, AA8007, AA8008, AA8010, AA8011, AA8011A,
AA8111, AA8211, AA8112, AA8014, AA8015, AA8016, AA8017, AA8018, AA8019,
AA8021, AA8021A, AA8021B, AA8022, AA8023, AA8024, AA8025, AA8026, AA8030,
AA8130, AA8040, AA8050, AA8150, AA8076, AA8076A, AA8176, AA8077, AA8177,
AA8079, AA8090, AA8091, and AA8093.
[0080] Clad layers as described herein can improve surface corrosion
resistance
properties of the products, improve pretreatment efficiency, and aid in
bending, riveting hole
piercing, and clinching.
[0081] In some examples, the alloy described herein for use as the clad
layer includes
zinc (Zn) in an amount of up to about 7.0 % (e.g., up to about 1.0 %, from
about 3.5 % to
about 6.0 %, from about 4.0 % to about 5.5 %, from about 0.05 % to about 0.25
%, or from
about 0.10 % to about 0.45 %) based on the total weight of the alloy. For
example, the alloy
can include about 0.01 %, about 0.02 %, about 0.03 %, about 0.04 %, about 0.05
%, about
0.06%, about 0.07 %, about 0.08 %, about 0.09 %, about 0.10 %, about 0.11 %,
about 0.12
%, about 0.13 %, about 0.14%, about 0.15 %, about 0.16%, about 0.17%, about
0.18%,
about 0.19%, about 0.20%, about 0.21 %, about 0.22%, about 0.23 %, about
0.24%, about
0.25 %, about 0.26%, about 0.27%, about 0.28%, about 0.29%, about 0.30%, about
0.31
%, about 0.32 %, about 0.33 %, about 0.34 %, about 0.35 %, about 0.36 %, about
0.37 %,
about 0.38 %, about 0.39 %, about 0.40 %, about 0.41 %, about 0.42 %, about
0.43 %, about
-20-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
0.44 %, about 0.45 %, about 0.46 %, about 0.47 %, about 0.48 %, about 0.49 %,
about 0.50
%, about 0.51 %, about 0.52 %, about 0.53 %, about 0.54 %, about 0.55 %, about
0.56 %,
about 0.57 %, about 0.58 %, about 0.59 %, about 0.60 %, about 0.61 %, about
0.62 %, about
0.63 %, about 0.64 %, about 0.65 %, about 0.66 %, about 0.67 %, about 0.68 %,
about 0.69
%, about 0.70 %, about 0.71 %, about 0.72 %, about 0.73 %, about 0.74 %, about
0.75 %,
about 0.76 %, about 0.77 %, about 0.78 %, about 0.79 %, about 0.80 %, about
0.81 %, about
0.82 %, about 0.83 %, about 0.84 %, about 0.85 %, about 0.86 %, about 0.87 %,
about 0.88
%, about 0.89 %, about 0.90 %, about 0.91 %, about 0.92 %, about 0.93 %, about
0.94 %,
about 0.95 %, about 0.96 %, about 0.97 %, about 0.98 %, about 0.99 %, about
1.0 %, about
1.1 %, about 1.2 %, about 1.3 %, about 1.4 %, about 1.5 %, about 1.6 %, about
1.7 %, about
1.8 %, about 1.9 %, about 2.0 %, about 2.1 %, about 2.2 o, about 2.3 %, about
2.4 %, about
2.5 %, about 2.6 %, about 2.7 %, about 2.8 %, about 2.9 %, about 3.0 %, about
3.1 %, about
3.2 %, about 3.3 %, about 3.4 %, about 3.5 %, about 3.6 %, about 3.7 %, about
3.8 %, about
3.9 %, about 4.0 %, about 4.1 %, about 4.2 %, about 4.3 %, about 4.4 %, about
4.5 %, about
4.600 about 4.7 %, about 4.800 about 4.9 %, about 5.000 about 5.100 about
5.200 about
5.3 %, about 5.4 %, about 5.5 %, about 5.6 %, about 5.7 %, about 5.8 %, about
5.9 %, about
6.0 %, about 6.1 %, about 6.2 %, about 6.3 %, about 6.4 %, about 6.5 %, about
6.6 %, about
6.7 %, about 6.8 %, about 6.9 %, or about 7.0 % Zn. In some cases, Zn is not
present in the
alloy (i.e., 0 %). All expressed in wt. %.
[0082] In some examples, the alloy described herein for use as the clad
layer also
includes magnesium (Mg) in an amount of up to about 6.00o (e.g., from about
0.200 to about
5.7 %, from about 1.2 % to about 3.3 %, from about 1.5 % to about 2.5 %, or
from about 4.0
% to about 4.8 %) based on the total weight of the alloy. For example, the
alloy can include
about 0.05 %, about 0.1 %, about 0.15 %, about 0.2 %, about 0.25 %, about 0.3
%, about 0.35
%, about 0.4 %, about 0.45 %, about 0.5 %, about 0.55 %, about 0.6 %, about
0.65 %, about
0.7 %, about 0.75 %, about 0.8 %, about 0.85 %, about 0.9 %, about 0.95 %,
about 1.0 %,
about 1.1 %, about 1.2 %, about 1.3 %, about 1.4 %, about 1.5 %, about 1.6 %,
about 1.7 %,
about 1.8 o, about 1.9 o, about 2.0 o, about 2.1 %, about 2.2 %, about 2.3 %,
about 2.4 o,
about 2.5 %, about 2.6 %, about 2.7 %, about 2.8 %, about 2.9 %, about 3.0 %,
about 3.1 %,
about 3.2 %, about 3.3 %, about 3.4 %, about 3.5 %, about 3.6 %, about 3.7 %,
about 3.8 %,
about 3.9 %, about 4.0 %, about 4.1 %, about 4.2 %, about 4.3 %, about 4.4 %,
about 4.5 %,
about 4.6 %, about 4.7 %, about 4.8 %, about 4.9 %, about 5.0 %, about 5.1 %,
about 5.2 %,
about 5.3 %, about 5.4 %, about 5.5 %, about 5.6 %, about 5.7 %, about 5.8 %,
about 5.9 %,
or about 6.0 % Mg. All expressed in wt. %.
-21-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
[0083] In some examples, the alloy described herein for use as the clad
layer can also
include copper (Cu) in an amount of up to about 0.35 % (e.g., from 0 % to
about 0.30 % or
from about 0.1 % to about 0.25 %) based on the total weight of the alloy. For
example, the
alloy can include about 0.01 %, about 0.02 %, about 0.03 %, about 0.04 %,
about 0.05 %,
about 0.06%, about 0.07%, about 0.08%, about 0.09%, about 0.10%, about 0.11 %,
about
0.12%, about 0.13 %, about 0.14%, about 0.15 %, about 0.16%, about 0.17%,
about 0.18
%, about 0.19 %, about 0.20 %, about 0.21 %, about 0.22 %, about 0.23 %, about
0.24 %,
about 0.25 %, about 0.26 %, about 0.27 %, about 0.28 %, about 0.29 %, about
0.30 %, about
0.31 %, about 0.32%, about 0.33 %, about 0.34%, or about 0.35 % Cu. In some
cases, Cu is
not present in the alloy (i.e., 0 %). All expressed in wt. %.
[0084] In some examples, the alloy described herein for use as the clad
layer also
includes silicon (Si) in an amount of from about 0.05 % to about 13.5 % (e.g.,
from about 0.1
% to about 13.0 %, from about 0.5 % to about 12.5 %, from about 1 % to about
10 %, from
about 2 % to about 8 %, from about 4 % to about 7 %, from about 0.05 % to
about 0.40 %,
from about 0.6 % to about 13.5 %, from about 0.10 % to about 0.35 % or from
about 0.15 %
to about 0.30 % Si) based on the total weight of the alloy. For example, the
alloy can include
about 0.05 %, about 0.06 %, about 0.07 %, about 0.08 %, about 0.09 %, about
0.10 %, about
0.11%, about 0.12 %, about 0.13 %, about 0.14 %, about 0.15 %, about 0.16 %,
about 0.17
%, about 0.18 %, about 0.19%, about 0.20%, about 0.21 %, about 0.22%, about
0.23 %,
about 0.24 %, about 0.25 %, about 0.26 %, about 0.27 %, about 0.28 %, about
0.29 %, about
0.30%, about 0.31 %, about 0.32%, about 0.33 %, about 0.34%, about 0.35 %,
about 0.36
%, about 0.37 %, about 0.38 %, about 0.39 %, about 0.40 %, about 0.41 %, about
0.42 %,
about 0.43 %, about 0.44 %, about 0.45 %, about 0.46 %, about 0.47 %, about
0.48 %, about
0.49 %, about 0.50 %, about 0.51 %, about 0.52 %, about 0.53 %, about 0.54 %,
about 0.55
%, about 0.56 %, about 0.57 %, about 0.58 %, about 0.59 %, about 0.60 %, about
0.61 %,
about 0.62 %, about 0.63 %, about 0.64 %, about 0.65 %, about 0.66 %, about
0.67 %, about
0.68 %, about 0.69 %, about 0.70 %, about 0.71 %, about 0.72 %, about 0.73 %,
about 0.74
%, about 0.75 %, about 0.76 %, about 0.77 %, about 0.78 %, about 0.79 %, about
0.80 %,
about 0.81 %, about 0.82 %, about 0.83 %, about 0.84 %, about 0.85 %, about
0.86 %, about
0.87 %, about 0.88 %, about 0.89 %, about 0.90 %, about 0.91 %, about 0.92 %,
about 0.93
%, about 0.94 %, about 0.95 %, about 0.96 %, about 0.97 %, about 0.98 %, about
0.99 %,
about 1.0%, about 1.1 %, about 1.2%, about 1.3 %, about 1.4%, about 1.5 %,
about 1.6%,
about 1.7%, about 1.8%, about 1.9%, about 2.0 %, about 2.1 %, about 2.2 %,
about 2.3%,
about 2.4 %, about 2.5 %, about 2.6 %, about 2.7 %, about 2.8 %, about 2.9 %,
about 3.0 %,
-22-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
about 3.1 %, about 3.2 %, about 3.3 %, about 3.4 %, about 3.5 %, about 3.6 %,
about 3.7 %,
about 3.8 %, about 3.9 %, about 4.0 %, about 4.1 %, about 4.2 %, about 4.3 %,
about 4.4 %,
about 4.5 %, about 4.6 %, about 4.7 %, about 4.8 %, about 4.9 %, about 5.0 %,
about 5.1 %,
about 5.2 %, about 5.3 %, about 5.4 %, about 5.5 %, about 5.6 %, about 5.7 %,
about 5.8 %,
about 5.9 %, about 6.0 %, about 6.1 %, about 6.2 %, about 6.3 %, about 6.4 %,
about 6.5 %,
about 6.6 %, about 6.7 %, about 6.8 %, about 6.9 %, about 7.0 %, about 7.1 %,
about 7.2 %,
about 7.3 %, about 7.4 %, about 7.5 %, about 7.6 %, about 7.7 %, about 7.8 %,
about 7.9 %,
about 8.0 %, about 8.1 %, about 8.2 %, about 8.3 %, about 8.4 %, about 8.5 %,
about 8.6 %,
about 8.7 %, about 8.8 %, about 8.9 %, about 9.0 %, about 9.1 %, about 9.2 %,
about 9.3 %,
about 9.4 %, about 9.5 %, about 9.6 %, about 9.7 %, about 9.8 %, about 9.9 %,
about 10.0 %,
about 10.1 %, about 10.2 %, about 10.3 %, about 10.4 %, about 10.5 %, about
10.6 %, about
10.7 %, about 10.8 %, about 10.9 %, about 11.0 %, about 11.1 %, about 11.2 %,
about 11.3
%, about 11.4 %, about 11.5 %, about 11.6 %, about 11.7 %, about 11.8 %, about
11.9 %,
about 12.0 %, about 12.1 %, about 12.2 %, about 12.3 %, about 12.4 %, about
12.5 %, about
12.600 about 12.700 about 12.800 about 12.900 about 13.000 about 13.1 %, about
13.2
%, about 13.3 %, about 13.4 o, or about 13.500 Si. All expressed in wt. %.
[0085] In some examples, the alloy described herein for use as the clad
layer also
includes iron (Fe) in an amount of from about 0.100o to about 0.900o (e.g.,
from about 0.20
% to about 0.60 %, from about 0.20 % to about 0.40 %, or from about 0.25 % to
about 0.35
%) based on the total weight of the alloy. For example, the alloy can include
about 0.10 %,
about 0.11 %, about 0.12 %, about 0.13 %, about 0.14 %, about 0.15 %, about
0.16 %, about
0.17 %, about 0.18 %, about 0.19 %, about 0.20 %, about 0.21 %, about 0.22 %,
about 0.23
%, about 0.24 %, about 0.25 %, about 0.26 %, about 0.27 %, about 0.28 %, about
0.29 %,
about 0.30 %, about 0.31 %, about 0.32 %, about 0.33 %, about 0.34 %, about
0.35 %, about
0.36 %, about 0.37 %, about 0.38 %, about 0.39 %, about 0.40 %, about 0.41 %,
about 0.42
%, about 0.43 %, about 0.44 %, about 0.45 %, about 0.46 %, about 0.47 %, about
0.48 %,
about 0.49 %, about 0.50 %, about 0.51 %, about 0.52 %, about 0.53 %, about
0.54 %, about
0.55 %, about 0.56 %, about 0.57 %, about 0.58 %, about 0.59 %, about 0.60 %,
about 0.61
%, about 0.62 %, about 0.63 %, about 0.64 %, about 0.65 %, about 0.66 %, about
0.67 %,
about 0.68 %, about 0.69 %, about 0.70 %, about 0.71 %, about 0.72 %, about
0.73 %, about
0.74 %, about 0.75 %, about 0.76 %, about 0.77 %, about 0.78 %, about 0.79 %,
about 0.80
%, about 0.81 %, about 0.82 %, about 0.83 %, about 0.84 %, about 0.85 %, about
0.86 %,
about 0.87 %, about 0.88 %, about 0.89 %, or about 0.90 % Fe. All expressed in
wt. %.
-23-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
[0086] In some examples, the alloy described herein for use as the clad
layer can also
include manganese (Mn) in an amount of up to about 1.5 % (e.g., from about 0.1
% to about
0.8%, from about 0.15 % to about 0.55 %, or from about 0.2% to about 0.35 %)
based on
the total weight of the alloy. For example, the alloy can include about 0.01
%, about 0.02 %,
about 0.03 %, about 0.04 %, about 0.05 %, about 0.06 %, about 0.07 %, about
0.08 %, about
0.09%, about 0.10 %, about 0.11 %, about 0.12 %, about 0.13 %, about 0.14 %,
about 0.15
%, about 0.16%, about 0.17%, about 0.18%, about 0.19%, about 0.20%, about 0.21
%,
about 0.22 %, about 0.23 %, about 0.24 %, about 0.25 %, about 0.26 %, about
0.27 %, about
0.28%, about 0.29%, about 0.30%, about 0.31 %, about 0.32%, about 0.33 %,
about 0.34
%, about 0.35 %, about 0.36 %, about 0.37 %, about 0.38 %, about 0.39 %, about
0.40 %,
about 0.41 %, about 0.42 %, about 0.43 %, about 0.44 %, about 0.45 %, about
0.46 %, about
0.47 %, about 0.48 %, about 0.49 %, about 0.50 %, about 0.51 %, about 0.52 %,
about 0.53
%, about 0.54 %, about 0.55 %, about 0.56 %, about 0.57 %, about 0.58 %, about
0.59 %,
about 0.60 %, about 0.61 %, about 0.62 %, about 0.63 %, about 0.64 %, about
0.65 %, about
0.66 %, about 0.67 %, about 0.68 %, about 0.69 %, about 0.70 %, about 0.71 %,
about 0.72
%, about 0.73 %, about 0.74 %, about 0.75 %, about 0.76 %, about 0.77 %, about
0.78 %,
about 0.79 %, about 0.80 %, about 0.81 %, about 0.82 %, about 0.83 %, about
0.84 %, about
0.85 %, about 0.86 %, about 0.87 %, about 0.88 %, about 0.89 %, about 0.90 %,
about 0.91
%, about 0.92 %, about 0.93 %, about 0.94 %, about 0.95 %, about 0.96 %, about
0.97 %,
about 0.98%, about 0.99%, about 1.0%, about 1.1 %, about 1.2%, about 1.3 %,
about 1.4
or about 1.5 % Mn. In some cases, Mn is not present in the alloy (i.e., 0 %).
All expressed
in wt. %.
[0087] In some examples, the alloy described herein for use as the clad
layer can also
include chromium (Cr) in an amount of up to about 0.35 % (e.g., from 0 % to
about 0.25 % or
from about 0.01 % to about 0.15 %) based on the total weight of the alloy. For
example, the
alloy can include about 0.01 %, about 0.02 %, about 0.03 %, about 0.04 %,
about 0.05 %,
about 0.06%, about 0.07%, about 0.08%, about 0.09%, about 0.10%, about 0.11%,
about
0.12%, about 0.13 %, about 0.14%, about 0.15 %, about 0.16%, about 0.17%,
about 0.18
%, about 0.19 %, about 0.20 %, about 0.21 %, about 0.22 %, about 0.23 %, about
0.24 %,
about 0.25 %, about 0.26 %, about 0.27 %, about 0.28 %, about 0.29 %, about
0.30 %, about
0.31 %, about 0.32 %, about 0.33 %, about 0.34 %, or about 0.35 % Cr. In some
cases, Cr is
not present in the alloy (i.e., 0 %). All expressed in wt. %.
[0088] In some examples, the alloy described herein for use as the clad
layer can also
include zirconium (Zr) in an amount of up to about 0.30 % (e.g., from 0 % to
about 0.20 % or
-24-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
from about 0.05 A to about 0.15 %) based on the total weight of the alloy.
For example, the
alloy can include about 0.01 %, about 0.02 %, about 0.03 %, about 0.04 %,
about 0.05 %,
about 0.06 %, about 0.07 %, about 0.08 %, about 0.09 %, about 0.10 %, about
0.11 %, about
0.12 %, about 0.13 %, about 0.14 %, about 0.15 %, about 0.16 %, about 0.17 %,
about 0.18
%, about 0.19 %, about 0.20 %, about 0.21 %, about 0.22 %, about 0.23 %, about
0.24 %,
about 0.25 %, about 0.26 %, about 0.27 %, about 0.28 %, about 0.29 %, or about
0.30 A Zr.
In some cases, Zr is not present in the alloy (i.e., 0 A). All expressed in
wt. %.
[0089] Optionally, the alloy described herein can further include other
minor elements,
sometimes referred to as impurities, in amounts of about 0.05 % or below,
about 0.04 % or
below, about 0.03% or below, about 0.02 % or below, or about 0.01 % or below
each, for
example. These impurities may include, but are not limited to, V, Ni, Sn, Ga,
Ca, Bi, Na, Pb,
or combinations thereof. Accordingly, V, Ni, Sn, Ga, Ca, Bi, Na, or Pb may be
present in
alloys in amounts of about 0.05 % or below, about 0.04 % or below, about 0.03
% or below,
about 0.0200 or below, or about 0.01 % or below. In some aspects, the sum of
all impurities
does not exceed about 0.15 A (e.g., about 0.10 %). All expressed in wt. %.
The remaining
percentage of the alloy is aluminum.
[0090] The thickness of each clad layer can be from about 1 A to about 25
% of the total
thickness of the clad aluminum alloy products described herein (e.g., from
about 1 A to about
12 %, or about 10 A). For example, in an aluminum alloy product having a
thickness of 1000
microns, each clad layer can have a thickness of about 10 microns to about 250
microns.
Optionally, each clad layer can have a thickness in the range of about 0.05 mm
to about 0.80
mm (e.g., about 0.10 mm to about 0.80 mm, about 0.10 mm to about 0.60 mm, or
about 0.20
mm to about 0.50 mm).
[0091] As described above, the clad aluminum alloy products can contain one
clad layer
or more than one clad layer. In some cases, the clad aluminum alloy products
contain only a
first clad layer. In some cases, the clad aluminum alloy products contain a
first clad layer and
a second clad layer. In some cases, the first clad layer and the second clad
layer are identical
in composition. In other cases, the first clad layer and the second clad layer
differ in
composition. The resulting clad aluminum alloy products exhibit excellent
balanced
properties, such as strength, formability, corrosion resistance, dent
resistance, and hemming
performance.
-25-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
Methods of Producing the Aluminum Alloys, Aluminum Alloy Products, and Clad
Aluminum
Alloy Products
[0092] The alloys described herein can be cast using any suitable casting
method. As a
few non-limiting examples, the casting process can include a direct chill (DC)
casting process
or a continuous casting (CC) process.
[0093] In addition, a clad layer as described herein can be attached to a
core layer as
described herein to form a clad aluminum alloy product by any means known to
persons of
ordinary skill in the art. For example, a clad layer can be attached to a core
layer by direct
chill co-casting (i.e., fusion casting) as described in, for example, U.S.
Patent Nos. 7,748,434
and 8,927,113, both of which are hereby incorporated by reference in their
entireties; by hot
and cold rolling a composite cast ingot as described in U.S. Patent No.
7,472,740, which is
hereby incorporated by reference in its entirety; or by roll bonding to
achieve the required
metallurgical bonding between the core and the clad layer; or by other methods
as known to
persons of ordinary skill in the art. The initial dimensions and final
dimensions of the clad
aluminum alloy products described herein can be determined by the desired
properties of the
overall final product.
[0094] The roll bonding process can be carried out in different manners.
For example, the
roll-bonding process can include both hot rolling and cold rolling. Further,
the roll bonding
process can be a one-step process or a multi-step process in which the
material is gauged
down during successive rolling steps. Separate rolling steps can optionally be
separated by
other processing steps, including, for example, annealing steps, cleaning
steps, heating steps,
cooling steps, and the like.
[0095] The co-cast ingot or other cast product can be processed by any
means known to
those of ordinary skill in the art. Optionally, the processing steps can be
used to prepare
sheets. Such processing steps include, but are not limited to, homogenization,
hot rolling,
cold rolling, solution heat treatment, and an optional pre-aging step, as
known to those of
ordinary skill in the art.
[0096] In the homogenization step of a DC casting process, the co-cast
ingot described
herein is heated to a temperature ranging from about 450 C to about 600 C.
For example,
the ingot can be heated to a temperature of about 450 C, about 460 C, about
470 C, about
480 C, about 490 C, about 500 C, about 510 C, about 520 C, about 530 C,
about 540
C, about 550 C, about 560 C, about 570 C, about 580 C, about 590 C, or
about 600 C.
The ingot is then allowed to soak (i.e., held at the indicated temperature)
for a period of time.
In some examples, the total time for the homogenization step, including the
heating and
-26-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
soaking phases, can be up to 24 hours. For example, the ingot can be heated up
to 550 C and
soaked, for a total time of up to 18 hours for the homogenization step.
Optionally, the ingot
can be heated to below 500 C and soaked, for a total time of greater than 18
hours for the
homogenization step.
[0097] Following the homogenization step of the co-cast ingot, a hot
rolling step can be
performed. Prior to the start of hot rolling, the homogenized ingot can be
allowed to cool to a
temperature of from about 300 C to about 450 C. For example, the homogenized
ingot can
be allowed to cool to a temperature of from about 325 C to about 425 C or
from about 350
C to about 400 C. The ingots can then be hot rolled at a temperature between
300 C to 450
C to form a hot rolled plate, a hot rolled shate or a hot rolled sheet having
a gauge of from
about 3 mm to about 200 mm (e.g., 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm,
9.5 mm,
mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65
mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 110 mm, 120 mm, 130 mm,
140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm, or anywhere in
between).
[0098] Optionally, the cast product can be a continuously cast product that
can be
allowed to cool after a high temperature continuous casting step to a
temperature of from
about 300 C to about 450 C. For example, the continuously cast product can
be allowed to
cool to a temperature of from about 325 C to about 425 C or from about 350
C to about
400 C. The continuously cast product can then be hot rolled at a temperature
of from about
300 C to about 450 C to form a hot rolled plate, a hot rolled shate or a hot
rolled sheet
having a gauge of from about 3 mm to about 200 mm (e.g., 3 mm, 4 mm, 5 mm, 6
mm, 7
mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm,
55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 110 mm,
120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm, or
anywhere in between). During hot rolling, temperatures and other operating
parameters can
be controlled so that the temperature of the clad alloy hot rolled product
upon exit from the
hot rolling mill is no more than about 470 C, no more than about 450 C, no
more than about
440 C, or no more than about 430 C.
[0099] The clad plate, shate, or sheet can then be cold rolled using
conventional cold
rolling mills and technology. Optionally, the cold rolled clad product (e.g.,
sheet or shate) can
have a gauge of from about 0.5 mm to about 10 mm, e.g., between about 0.7 mm
to about 6.5
mm. Optionally, the cold rolled clad sheet can have a gauge of 0.5 mm, 1.0 mm,
1.5 mm, 2.0
mm, 2.5 mm, 3.0 mm, 3.5 mm, 4.0 mm, 4.5 mm, 5.0 mm, 5.5 mm, 6.0 mm, 6.5 mm,
7.0 mm,
7.5 mm, 8.0 mm, 8.5 mm, 9.0 mm, 9.5 mm, or 10.0 mm. The cold rolling can be
performed
-27-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
to result in a final gauge thickness that represents a gauge reduction of up
to about 85 % (e.g.,
up to about 10 %, up to about 20 %, up to about 30 %, up to about 40 %, up to
about 50 %,
up to about 60 %, up to about 70 %, up to about 80 %, or up to about 85 %
reduction).
Optionally, an interannealing step can be performed during the cold rolling
step. The
interannealing step can be performed at a temperature of from about 300 C to
about 450 C
(e.g., about 310 C, about 320 C, about 330 C, about 340 C, about 350 C,
about 360 C,
about 370 C, about 380 C, about 390 C, about 400 C, about 410 C, about
420 C, about
430 C, about 440 C, or about 450 C). In some cases, the interannealing step
comprises
multiple processes. In some non-limiting examples, the interannealing step
includes heating
the cold rolled clad plate, shate, or sheet to a first temperature for a first
period of time
followed by heating to a second temperature for a second period of time. For
example, the
cold rolled clad plate, shate, or sheet can be heated to about 410 C for
about 1 hour and then
heated to about 330 C for about 2 hours.
[0100] Subsequently, the clad plate, shate, or sheet can undergo a solution
heat treatment
step. The solution heat treatment step can include any conventional treatment
for the clad
sheet which results in solutionizing of the soluble particles. The clad plate,
shate, or sheet can
be heated to a peak metal temperature (PMT) of up to about 590 C (e.g., from
about 400 C
to about 590 C) and soaked for a period of time at the temperature. For
example, the clad
plate, shate, or sheet can be soaked at about 550 C for a soak time of up to
about 30 minutes
(e.g., 0 seconds, about 60 seconds, about 75 seconds, about 90 seconds, about
5 minutes,
about 10 minutes, about 20 minutes, about 25 minutes, or about 30 minutes).
After heating
and soaking, the clad plate, shate, or sheet is rapidly cooled at rates
greater than 50 C/second
( C/s) to a temperature from about 500 C to about 200 C. In one example, the
clad plate,
shate, or sheet is cooled at a quench rate of above 200 C/s from a
temperature of about 450
C to a temperature of about 200 C. Optionally, the cooling rates can be
faster in other cases.
[0101] After quenching, the clad plate, shate or sheet can optionally
undergo a pre-aging
treatment by reheating the plate, shate, or sheet before coiling. The pre-
aging treatment can
be performed at a temperature of from about 50 C to about 150 C for a period
of time of up
to about 6 hours. For example, the pre-aging treatment can be performed at a
temperature of
about 50 C, about 55 C, about 60 C, about 65 C, about 70 C, about 75 C,
about 80 C,
about 85 C, about 90 C, about 95 C, about 100 C, about 105 C, about 110 C,
about 115
C, about 120 C, about 125 C, about 130 C, about 135 C, about 140 C, about
145 C, or
about 150 C. Optionally, the pre-aging treatment can be performed for about
30 minutes,
about 1 hour, about 2 hours, about 3 hours, about 4 hours, about 5 hours, or
about 6 hours.
-28-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
The pre-aging treatment can be carried out by passing the plate, shate, or
sheet through a
heating device, such as a device that emits radiant heat, convective heat,
induction heat,
infrared heat, or the like.
[0102] The co-cast ingots or other co-cast products described herein can
also be used to
make products in the form of plates or other suitable products. The products
can be made
using techniques as known to those of ordinary skill in the art. For example,
plates including
the clad products as described herein can be prepared by processing a co-cast
ingot in a
homogenization step or casting a co-cast product in a continuous caster
followed by a hot
rolling step. In the hot rolling step, the cast product can be hot rolled to a
200 mm thick gauge
or less (e.g., from about 10 mm to about 200 mm). For example, the cast
product can be hot
rolled to a plate having a final gauge thickness of about 10 mm to about 175
mm, about 15
mm to about 150 mm, about 20 mm to about 125 mm, about 25 mm to about 100 mm,
about
30 mm to about 75 mm, or about 35 mm to about 50 mm.
Methods of Using the Aluminum Alloy Products and Clad Aluminum Alloy Products
[0103] The aluminum alloy products and the clad aluminum alloy products
described
herein can each be used in automotive applications and other transportation
applications,
including aircraft and railway applications. For example, the aluminum alloy
products and the
clad aluminum alloy products can be used to prepare automotive structural
parts, such as
bumpers, side beams, roof beams, cross beams, pillar reinforcements (e.g., A-
pillars, B-
pillars, and C-pillars), inner panels, outer panels, side panels, inner hoods,
outer hoods, or
trunk lid panels. The aluminum alloy products and the clad aluminum alloy
products and
methods described herein can also be used in aircraft or railway vehicle
applications, to
prepare, for example, external and internal panels. In some examples, the
aluminum alloy
products and the clad aluminum alloy products can be used in aerospace
structural and non-
structural parts or in marine structural or non-structural parts.
[0104] The aluminum alloy products and the clad aluminum alloy products and
methods
described herein can also be used in electronics applications. For example,
the aluminum
alloy products and the clad aluminum alloy products and methods described
herein can be
used to prepare housings for electronic devices, including mobile phones and
tablet
computers. In some examples, the aluminum alloy products and the clad aluminum
alloy
products can be used to prepare housings for the outer casings of mobile
phones (e.g., smart
phones) and tablet bottom chassis.
-29-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
[0105] The aluminum alloy products and the clad aluminum alloy products and
methods
described herein can also be used in other applications as desired. The
aluminum alloy
products described herein can be provided as aluminum alloy sheets and/or
plates suitable for
further processing by an end user. The clad aluminum alloy products described
herein can be
provided as clad aluminum alloy sheets and/or clad aluminum alloy plates
suitable for further
processing by an end user. For example, an aluminum alloy sheet or a clad
aluminum alloy
sheet can be further subjected to surface treatments by an end user for use as
an architectural
skin panel for aesthetic and structural purposes.
[0106] The following examples will serve to further illustrate the present
invention
without, at the same time, however, constituting any limitation thereof On the
contrary, it is
to be clearly understood that resort may be had to various embodiments,
modifications and
equivalents thereof which, after reading the description herein, may suggest
themselves to
those skilled in the art without departing from the spirit of the invention.
During the studies
described in the following examples, conventional procedures were followed,
unless
otherwise stated. Some of the procedures are described below for illustrative
purposes.
Examples
Aluminum Alloys
[0107] Aluminum alloys were produced by direct chill casting to prepare a
70 x 220 mm
ingot and scalping the ingot to 60 x 220 mm. The aluminum alloy samples were
homogenized
by adding heat at 50 C/h and holding for 10 hours at 550 C. Samples were
then hot rolled to
9.5 mm. Coil cooling was simulated in a furnace shut down at 400 C. Samples
were cold
rolled to 1 mm. Samples were then solutionized at 570 C/60 s + 10 s heating
and the samples
were then quenched using air fans. The samples in a T4 temper were then tested
for
mechanical properties, as detailed below.
[0108] As shown in Table 1, Comparative Alloy 1 was intended to be
representative of
the existing art and was prepared as a comparative to Example Alloys 1-6.
Example Alloys 4
and 5 were prepared with an increased recycling content of up to 50 wt. % UBC.
Table 1
Elemen
Aluminum Alloy Compositions (wt. %)
Ex. Ex. Ex. Ex. Ex. Ex. Comp
Alloy Alloy Alloy Alloy Alloy Alloy .Alloy
1 2 3 4 5 6 1
Si 0.34 0.35 0.35 0.37 0.38 0.40 0.12
-30-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
Mg 1.17 1.39 1.16 1.18 1.37 1.43 4.36
Fe 0.21 0.20 0.19 0.29 0.34 0.25 0.26
Cu 0.12 0.11 0.28 0.14 0.36 0.35 0.03
Mn 0.09 0.08 0.08 0.40 0.34 0.22 0.32
Cr 0.01 0.01 0.01 0.01 0.01 0.014 0.03
Ti 0.02 0.02 0.02 0.02 0.02 0.02 0.02
Zn -- 0.014 --
101091 All expressed in wt. %. Up to 0.25 wt. % impurities. "--" indicates
not reported.
Remainder is Al.
Aluminum Alloy Properties
[0110] Tensile tests for Comparative Alloy 1 and Example Alloys 1-6 were
performed.
The formability of the samples was measured in the longitudinal (L), diagonal
(D), and
transverse (T) directions using ISO/EN A80 for total elongation and ISO/EN Ag
for uniform
elongation. FIGS. 1-4 show the A80 and Ag elongations (respectively) for
Comparative
Alloy 1 and Example Alloys 1-5. As shown in FIGs. 1 (total elongation) and 2
(uniform
elongation), Example Alloys 1-3 show similar or better elongation than
Comparative Alloy 1.
Similarly, as shown in FIGs. 3 (total elongation) and 4 (uniform elongation),
Example Alloys
4 and 5 with high recycled content show good elongation comparable to
Comparative Alloy
1, which is unexpected for having high recycled content.
[0111] Tensile tests were also used to measure r and n values for the
samples using ISO
10113 (2006) and ISO 10275 (2007). As is apparent from FIG. 5, Example Alloys
1-3 show
good r values at a strain range from 10 % to 15 %, in excess of Comparative
Alloy 1 in the L
and T directions. Similarly, FIG. 6 demonstrates that Example Alloys 4 and 5
show good r
values against Comparative Alloy 1 while having high recycled content.
[0112] The bending properties of the samples were measured using an f-
factor test (also
known as the R/t ratio, where R is the radius of the tool (die) used and t is
the thickness of the
material) at 10% elongation. Results averaged over multiple runs are shown in
FIG. 7.
Example Alloys 1-5 demonstrated sufficient bending comparable to Comparative
Alloy 1.
Example Alloys 4 and 5 achieved this even with their high recycling content.
[0113] Example Alloy 6 was also tested. Reducing the Fe and Mn content
resulted in
increased n and r values and improved bending, while increasing Cr content
lowered
elongation but improved bending.
-31-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
Illustrations
[0114] Illustration 1 is an aluminum alloy, comprising from about 0.5 wt. %
to about 1.6
wt. % Mg; from about 0.20 wt. % to about 0.5 wt. % Si; up to about 1.0 wt. %
Fe; up to about
0.5 wt. % Cu; up to about 0.5 wt. % Mn; up to about 0.3 wt. % Cr; up to about
0.3 wt. % Ti;
up to about 0.5 wt. % Zn; up to about 0.25 wt. % impurities; and Al.
[0115] Illustration 2 is an aluminum alloy, comprising from about 0.6 wt. %
to about 1.5
wt. % Mg; from about 0.3 wt. % to about 0.45 wt. % Si; up to about 0.5 wt. %
Fe; up to about
0.4 wt. % Cu; up to about 0.4 wt. % Mn; up to about 0.25 wt. % Cr; up to about
0.15 wt. %
Ti; up to about 0.4 wt. % Zn; up to about 0.20 wt. % impurities; and Al.
[0116] Illustration 3 is the aluminum alloy of any of the preceding or
subsequent
illustrations, wherein the Mg and Si are present in a ratio of from about 5:1
to about 2:1 of
Mg to Si by weight.
[0117] Illustration 4 is the aluminum alloy of any of the preceding or
subsequent
illustrations, wherein the Mg and Si are present in a ratio of from about 4:1
to about 2:1 of
Mg to Si by weight.
[0118] Illustration 5 is the aluminum alloy of any of the preceding or
subsequent
illustrations, further comprising from about 0.01 wt. % to about 0.5 wt. % Cu.
[0119] Illustration 6 is the aluminum alloy of any of the preceding or
subsequent
illustrations, further comprising from about 0.01 wt. % to about 0.5 wt. % Mn.
[0120] Illustration 7 is the aluminum alloy of v, further comprising from
about 0.01 wt.
% to about 0.25 wt. % Ti.
[0121] Illustration 8 is the aluminum alloy of any of the preceding or
subsequent
illustrations, further comprising from about 0.01 wt. % to about 1.0 wt. % Fe.
[0122] Illustration 9 is the aluminum alloy of any of the preceding or
subsequent
illustrations, further comprising from about 0.005 wt. % to about 0.30 wt. %
Cr.
[0123] Illustration 10 is the aluminum alloy of any of the preceding or
subsequent
illustrations, further comprising from about 0.60 wt. % to about 1.4 wt. % Mg.
[0124] Illustration 11 is the aluminum alloy of any of the preceding or
subsequent
illustrations, further comprising from about 0.25 wt. % to about 0.41 wt. %
Si.
[0125] Illustration 12 is the aluminum alloy of any of the preceding or
subsequent
illustrations, further comprising from about 0.30 wt. % to about 0.40 wt. %
Si.
-32-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
[0126] Illustration 13 is the aluminum alloy of any of the preceding or
subsequent
illustrations, wherein the aluminum alloy, when in a T8x temper, has a yield
strength (Rp0.2)
of from about 160 MPa to about 230 MPa tested according to ISO 6892-1 (2016).
[0127] Illustration 14 is the aluminum alloy of any of the preceding or
subsequent
illustrations, wherein the aluminum alloy has a bake hardening value from
about 70 MPa to
about 140 MPa.
[0128] Illustration 15 is the aluminum alloy of any of the preceding or
subsequent
illustrations, comprising at least about 40 wt. % recycled content.
[0129] Illustration 16 is the aluminum alloy of any of the preceding or
subsequent
illustrations, comprising at least about 40 wt. % UBC.
[0130] Illustration 17 is the aluminum alloy of any of the preceding or
subsequent
illustrations, wherein the combined concentration of Fe, Mn and Cu in the
aluminum alloy is
at least 0.7 wt. %.
[0131] Illustration 18 is the aluminum alloy of any of the preceding or
subsequent
illustrations, wherein the combined concentration of Fe, Mn, and Cu in the
aluminum alloy is
between about 0.9 wt. % and about 3.0 wt. %.
[0132] Illustration 19 is the aluminum alloy of any of the preceding or
subsequent
illustrations, wherein the aluminum alloy is a core layer in a clad product.
[0133] Illustration 20 is a monolithic sheet, comprising the aluminum alloy
of any of the
previous illustrations.
[0134] Illustration 21 is a clad aluminum alloy product, comprising: a core
layer having a
first side and a second side; and a first clad layer in contact with the first
side of the core
layer, wherein the core layer comprises from about 0.5 wt. % to about 1.6 wt.
% Mg and from
about 0.2 wt. % to about 0.5 wt. % Si.
[0135] Illustration 22 is the clad aluminum alloy product any of the
preceding or
subsequent illustrations, wherein the Mg and Si are present in the core layer
at a ratio of from
about 5:1 to about 2:1 of Mg to Si by weight.
[0136] Illustration 23 is the clad aluminum alloy product any of the
preceding or
subsequent illustrations, wherein the core layer comprises from about 0.60 wt.
% to about 1.4
wt. % Mg.
[0137] Illustration 24 is the clad aluminum alloy product any of the
preceding or
subsequent illustrations, wherein the core layer comprises from about 0.30 wt.
% to about
0.40 wt. % Si.
-33-

CA 03126851 2021-07-14
WO 2020/185920 PCT/US2020/022133
[0138] Illustration 25 is the clad aluminum alloy product any of the
preceding or
subsequent illustrations, wherein the first clad layer has a thickness of
about 0.05 mm to
about 0.80 mm.
[0139] Illustration 26 is the clad aluminum alloy product any of the
preceding or
subsequent illustrations, wherein the core layer has a thickness of about 0.7
to about 2.3 mm.
[0140] Illustration 27 is the clad aluminum alloy product any of the
preceding or
subsequent illustrations, further comprising a second clad layer in contact
with the second
side of the core layer.
[0141] Illustration 28 is the clad aluminum alloy product any of the
preceding or
subsequent illustrations, wherein the first clad layer comprises an lxxx
series aluminum
alloy, 2xxx series aluminum alloy, a 3xxx series aluminum alloy, a 4xxx series
alloy, a 5xxx
series aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum
alloy, or an
8xxx series aluminum alloy.
[0142] Illustration 29 is the clad aluminum alloy product any of the
preceding or
subsequent illustrations, wherein the clad aluminum alloy product when in a
T8x temper has
a yield strength of at least about 150 MPa.
[0143] Illustration 30 is the clad aluminum alloy product any of the
preceding or
subsequent illustrations, wherein the clad aluminum alloy product has a total
elongation
above 20 % in all directions.
[0144] Illustration 31 is the clad aluminum alloy product any of the
preceding or
subsequent illustrations, wherein the clad aluminum alloy product is a sheet,
a plate, an
electronic device housing, an automotive structural part, an aerospace
structural part, an
aerospace non-structural part, a marine structural part, or a marine non-
structural part.
[0145] All patents, publications and abstracts cited above are incorporated
herein by
reference in their entirety. Various embodiments of the invention have been
described in
fulfillment of the various objectives of the invention. It should be
recognized that these
embodiments are merely illustrative of the principles of the present
invention. Numerous
modifications and adaptations thereof will be readily apparent to those
skilled in the art
without departing from the spirit and scope of the present invention as
defined in the
following claims.
-34-

Representative Drawing